JP2024516257A - Foldable and transportable buildings - Google Patents

Abstract

A spacer system for laminated building structures that matingly engages with seal plates on the ends of the housing components, and a fork tube arrangement to facilitate movement of the shipping module. (Figure 1)

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 17/527,520, filed November 16, 2021, which is a continuation-in-part of PCT patent application PCT/US2021/059440, filed November 16, 2021, which claims the benefit of U.S. Provisional Patent Application No. 63/188,101, filed May 13, 2021, and U.S. Provisional Patent Application No. 63/136,268, filed January 12, 2021. This application is a continuation-in-part of PCT patent application PCT/US2021/056415, filed October 25, 2021, which also claims the benefit of U.S. Provisional Patent Application No. 63/196,400, filed June 3, 2021, U.S. Provisional Patent Application No. 63/181,447, filed April 29, 2021, and U.S. Provisional Patent Application No. 63/136,268, filed January 12, 2021, and this application claims the benefit of U.S. Provisional Patent Application No. 63/188,101, filed May 13, 2021, U.S. Provisional Patent Application No. 63/181,447, filed April 29, 2021, and U.S. Provisional Patent Application No. 63/192,349, filed May 24, 2021.

The present invention relates to structures such as dwellings and other buildings for residential occupancy, commercial occupancy and/or material storage, and components of such structures.

In the residential sector, the traditional technique for building a house is called "stick-built" construction, where builders construct the house at its intended location using mostly raw materials such as wooden boards, plywood panels, and steel columns. The materials are assembled piece by piece on a pre-prepared portion of the ground, such as a cast-in-place concrete slab, or a cast-in-place concrete or cinder block foundation.

In order to reduce costs, there have been many attempts to move away from traditional construction techniques used to create residential and commercial spaces. In this regard, significant advances have been made by the inventors in the construction of residential and commercial spaces, as exemplified by patents including U.S. Pat. Nos. 8,474,194, 8,733,029, 10,688,906, 10,829,029, 10,926,689, and 11,220,816, which are directed to the in-factory manufacture of wall, floor, and roof components that fold together into compact shipping modules that are then transported to the intended location and unfolded to provide a fully formed structure.

In one form, the invention relates to a spacer system for stacked housing components having a first housing component having a horizontal first surface, an opposing horizontal second surface, and an end having an end length, and an elongated planar second seal plate having a first seal plate end, an opposing second seal plate end, a seal plate outer surface, an opposing seal plate inner surface, and a seal plate thickness. The first seal plate end includes a first set of stepped locating ridges extending from the first seal plate end toward the second seal plate end and inwardly of the seal plate thickness, the seal plate inner surface being secured to the end of the first housing component. A spacer plate is also provided including a spacer plate outer surface, an opposing spacer plate inner surface, a spacer plate thickness, and a planar base having a lip extending away from the spacer plate inner surface, the lip having an end distal from the spacer plate inner surface having a second set of stepped locating ridges. The spacer plate inner surface is positioned against a horizontal first surface of the first housing component adjacent the end of the first housing component, and the second set of stepped locating ridges are in a mating relationship with the first set of stepped locating ridges.

In another aspect of the invention, a folded building structure transportable to a location where construction is desired has a fixed space portion including a planar, rectangular first floor portion having first and second longitudinal floor ends, first and second transverse floor ends, and a thickness, the first floor portion having, in the thickness direction, (i) a first structural layer having a first surface and an opposing second surface, (ii) a foam panel layer having a first surface and an opposing second surface, the first surface of the foam panel layer being bonded to the opposing second surface of the first structural layer, (iii) a second structural layer having a first surface and an opposing second surface, the first surface of the second structural layer being bonded to the opposing second surface of the foam panel layer, and (iv) a first end reinforcement portion adjacent to the first longitudinal floor end and a second end reinforcement portion adjacent to the second longitudinal floor end. Between the first structural layer and the second structural layer, the first floor portion has (i) a first fork tube oriented in a transverse direction and spanning the distance from the first longitudinal floor end to the second longitudinal floor end to define a first opening at the first longitudinal floor end and a second opening at the second longitudinal floor end, (ii) a planar, elongated, longitudinally oriented first fork tube plate secured to the first end reinforcement and the first fork tube, and (iv) a planar, elongated, longitudinally oriented second fork tube plate secured to the second end reinforcement and the first fork tube.

These and other aspects of the invention are described in the accompanying drawings and in the following preferred embodiments and claims.

FIG. 1 is a perspective view of a structure obtained according to the present invention. FIG. 2 is a schematic plan view of the structure shown in FIG. 1 . FIG. 2 is an end view of the shipping module from which the finished structure shown in FIG. 1 is formed. FIG. 2 is a partial cutaway view of a completed structure according to the present invention showing more detailed configurations of the roof, wall and floor components. FIG. 2 is a partial cutaway view of a completed structure according to the present invention showing more detailed configurations of the roof, wall and floor components. FIG. 2 is a schematic perspective view showing an outer edge reinforcement of a wall component according to the invention; 1 is an exploded cross-sectional view of a multi-layer, laminate design for use in a housing component according to the present invention. FIG. 8A is a perspective view of a collapsible I-beam for a floor component according to the present invention with the beam in a non-folded position, and FIG. 8B is a side view of a collapsible I-beam for a floor component according to the present invention with the beam in a folded position. FIG. 9A is a schematic perspective view of a fork tube arrangement of a floor section according to the present invention; FIG. 9B is a schematic cutaway perspective view of a fork tube arrangement disposed within a floor section according to the present invention; and FIG. 9C is a schematic cutaway perspective view of a floor component according to the present invention. FIG. 2 is a schematic side view of an I-beam end cap according to the present invention. FIG. 11A is a cross-sectional view of a compression seal according to the present invention, and FIG. 11B is a side view of a roof bottom plate with a compression seal in one of two seal slots according to the present invention. FIG. 12 is an exploded side view of a joint between a wall vertical interlock and a wall end cap in accordance with the present invention. FIG. 13 is an exploded side view of a joint between a roof bottom plate and a wall end cap according to the present invention. FIG. 14 is an exploded side view of the joint between the I-beam interlock A and the I-beam interlock B according to the present invention. FIG. 15 is an exploded side view of a floor top plate and wall end cap joint according to the present invention. FIG. 16A is a cross-sectional view of a shear seal according to the present invention, and FIG. 16B is a side view of a wall end interlock having a shear seal according to the present invention disposed in its seal slot. FIG. 17 is an exploded side view of the floor top interlock and wall end interlock A joint according to the present invention. FIG. 18 is an exploded side view of the joint between wall end interlock B and wall end interlock A according to the present invention. FIG. 19A is a side view showing the joint between the perimeter board and the I-beam end cap of the present invention, and FIG. 19B is an explanatory diagram showing the positional relationship between the I-beam end cap, floor top plate, wall end cap and perimeter board of the present invention. FIG. 2 is a side view of a roof skirt board to I-beam end lock joint according to the present invention. FIG. 21A is an exploded perspective view of a completed structure according to the present invention showing a preferred position of the seal system of the present invention on a horizontally oriented housing component, and FIG. 21B is an exploded perspective view of a completed structure according to the present invention showing a corresponding preferred position of the seal system of the present invention on a vertically oriented housing component. 1 shows the layout of a three-chamber structure made in accordance with the present invention. 1 is a perspective view of a two-storey structure constructed in accordance with the present invention; 1 is a perspective view of an exemplary spacer plate according to the present invention. FIG. 13 is a side view showing the placement of spacer plates in relation to two laminate structures.

EMBODIMENTS An embodiment of a foldable, transportable structure 150 that may be implemented in accordance with the invention set forth herein is shown in Figures 1-5. As illustrated in Figure 1, when fully deployed, the structure 150 has a rectangular shape formed from three generally planar, rectangular (including rectangular, square, or rectangular-like) housing components 155, which are comprised of a wall component 200, a floor component 300, and a roof component 400. As shown in Figures 1 and 2, the perimeter of the structure 150 is defined by a first longitudinal end 106, a first transverse end 108, a second longitudinal end 116, and a second transverse end 110. For convenience, the direction parallel to the first longitudinal end 106 and the second longitudinal end 116 may be referred to as the "longitudinal direction", the direction parallel to the first transverse end 108 and the second transverse end 110 may be referred to as the "transverse direction", and the direction parallel to the vertical direction of Figure 1 may be referred to as the "vertical" direction. The illustrated structure 150 has one floor component 300, one roof component 400, and four wall components 200, although it should be understood that the present invention is applicable to structures having other configurations.

The housing components 155 (wall components 200, floor components 300, and roof components 400) can be fabricated and dimensioned as described herein and arranged together to form the shipping module 100, an end view of which is shown in FIG. 3. The housing components 155 are dimensioned so that the shipping module 100 fits within the dimensional limits of U.S. federal highways. As a result, the shipping module 100 can be more easily transported on restricted highways and can be transported with appropriate transportation equipment without the need for large permits. In this manner, the basic components of the structure 150 can be manufactured in a factory and arranged together to form the shipping module 100, which can be transported to the desired site of the structure as described herein and easily assembled there.
Housing component (155) general description

The housing component 155 of the present invention includes many shared design features, which are described below.
A. Laminated structural design

The housing component 155 can be manufactured using a multi-layer laminate design. A particular laminate design that can be used to manufacture the housing component 155 includes a first structural layer 210, a foam panel layer 213, a second structural layer 215, and a protective layer 218, as shown in FIG. 7 and described below.

In particular, a first structural layer 210 is provided in the embodiment of the housing component 155 shown in FIG. 7. The first structural layer 210 in the illustrated embodiment includes a sheet metal layer 205, which may be, for example, galvanized steel or aluminum. The sheet metal layer 205 is formed from a plurality of generally planar rectangular metal plates 206 arranged adjacent to one another to generally cover the entire area of the intended housing component 155.

7, next, in the illustrated embodiment of the housing component 155, a foam panel layer 213 is provided formed from a plurality of generally planar rectangular foam panels 214 collectively representing the first surface 211 and the second opposing surface 212. The foam panels 214 are, for example, made of expanded polystyrene (EPS). A number of these foam panels 214 are placed adjacent to one another and superimposed first side down on the first structural layer 210 to generally cover the entire area of the intended housing component 155. The foam panels 214 of the foam panel layer 213 are preferably secured to the metal sheet 205 of the first structural layer 210 using a suitable adhesive, preferably a polyurethane-based construction adhesive. The foam panel layer 213 may include an outer edge reinforcement and an inner edge reinforcement, as further described below.

7, a second structural layer 215 is then provided, the second structural layer 215 having a first surface positioned on the second opposing surface 212 (distal from the first structural layer 210) opposite the foam panel 214, and also having a second opposing surface. The second structural layer 215 in the illustrated embodiment includes a sheet metal layer 216, which may be, for example, galvanized steel or aluminum. The sheet metal layer 216 is formed from a plurality of generally planar rectangular metal plates 217 arranged adjacent to each other to generally cover the entire area of the intended housing component 155 and superimposed first side down on the second opposing surface of the foam panel layer 213. The metal plates 217 of the second structural layer 215 are preferably secured to the foam panel layer 213 using a suitable adhesive, preferably a polyurethane-based construction adhesive.

7, the optional protective layer 218 is then provided, which has a first surface positioned on the second opposing surface of the second structural layer 215 (the surface distal from the foam panel layer 213) and also has a second opposing surface. The optional protective layer 218 in the illustrated embodiment includes a plurality of rectangular structural building panels 219, which are essentially made of a relatively high strength inorganic composition such as magnesium oxide (MgO). The structural foam panels 214 are placed adjacent to each other and superimposed first side down on the first structural layer 210 to generally cover the entire area of the intended housing component 155. The building panels 219 of the protective layer 218 are preferably secured to the second structural layer 215 using a suitable adhesive, preferably a polyurethane-based building adhesive. The protective layer 218 can be used as needed to provide a degree of fire resistance to the housing component 155 as well as a desired texture and/or feel.

Other embodiments of multi-layer, laminate designs that can be used to make the housing components 155 of the present invention are described in U.S. Non-Provisional Patent Application No. 16/786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed February 10, 2020, and issued as U.S. Patent No. 11,118,344. The contents of U.S. Non-Provisional Patent Application No. 16/786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed February 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the multi-layer, laminate designs described, for example, in paragraphs 0034-57 and shown in Figures 4A-4D thereof.
B. Reinforcement of the outer edge of the housing component

An outer edge reinforcement may be provided at the outer edge of each housing component 155 (i.e., the members that define the peripheral edge of the housing component 155), if desired. The outer edge reinforcement has a longitudinal stiffening member that may protect the foam material of the foam panel layer 213 that would otherwise be exposed at the outer edge of the housing component 155. The outer edge reinforcement may be fabricated from one or more of laminated strand lumber board, wood board, C-channel extruded aluminum or steel, or the like, and is typically secured to the outer edge of the housing component 155 using fasteners, such as screws or nail fasteners, and/or adhesives.
C. Partitioning of chassis components

The housing component 155 in certain instances is partitioned, sectioned, or partitioned into housing component portions to facilitate the formation of a compact shipping module 100. In those instances where the housing component 155 is partitioned into housing component portions, any outer edge reinforcements at the outer edges that define the peripheral edges of the housing component are split between or among two or more of the portions, as needed.

The housing component portions can be joined by a hinge structure or mechanism that allows the housing component portions to “fold” together, thereby contributing to forming a compact shipping module 100.
D. Reinforcement of the inner edge of the housing component

The housing component 155 partitioned into housing component portions will have an inner edge. There will be two adjacent inner edges for every pair of adjacent housing component portions. Such inner edges may be provided with an inner edge reinforcement. Like the outer edge reinforcement, such inner edge reinforcement will have a longitudinal stiffening member that can protect the foam material of the foam panel layer 213 that would otherwise be exposed at the outer edge of the housing component 155. The inner edge reinforcement may be made from one or more of laminated strand lumber board, wood board, C-channel extruded aluminum or steel, and the like, and is typically secured to the inner edge of the housing component 155 using fasteners such as screws or nails, and/or adhesives.
E. Load transfer of housing components

For the enclosure components 155, it is necessary to transfer loads imposed on its surface to its outer ends, where they are transferred to adjacent walls, through adjacent wall components, or to the building foundation. For enclosure components 155 that are oriented horizontally in use (floor components 300 and roof components 400), such loads include the weight of equipment, furniture, and people borne by its surfaces, as well as vertical seismic loads. For enclosure components that are oriented vertically in use (wall components 200), such loads include loads resulting from weather conditions (hurricanes, tornadoes, etc.) and human actions (impact of vehicles and other objects).

To this end, a multi-layer, laminate design such as that shown in FIG. 7 would function to transfer the loads described above. To add additional load-transfer capabilities, structural members such as beams and/or joists may be utilized within the perimeter edges of the housing components 155 to assist in load transfer to the outer edges, as deemed appropriate for the particular design of the structure 150 and the particular housing component 155. A particular embodiment of such a structural component, also incorporating a hinge structure, is described in U.S. Non-Provisional Patent Application No. 17/527,520, entitled "Folding Beam Systems," filed on November 16, 2021, and having the same inventor as the present disclosure. The contents of this U.S. Non-Provisional Patent Application No. 17/527,520, entitled "Folding Beam Systems," filed on November 16, 2021, and having the same inventor as the present disclosure, are incorporated by reference as if fully set forth herein. See in particular the description of the hinged load transfer components in, for example, paragraphs 0074-0089 and 0104-0126 and Figures 8A-13E and 15A-24A thereof, and the description of the associated end hinge assemblies in, for example, paragraphs 0090-0093 and 0127-0132 and Figures 14A-14B, 24B and 25A-25D thereof.

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

Typically, the structure 150 utilizes four wall components 200 , with each wall component 200 corresponding to an entire wall of the structure 150 .
A. Overview

The wall component 200 has a generally rectangular peripheral edge. As shown in FIG. 1, the wall component 200 has a plurality of openings, specifically a door opening 202 having a door frame and door assembly, and a plurality of window openings 204, each having a window frame and window assembly. The height and length of the wall component 200 may vary according to design preferences, if desired, and subject to the dimensional limitations applicable to shipping as discussed above. In the present disclosure, the structure 150 is formed with all sides of equal length, and therefore, its first and second longitudinal ends 106 and 116, and its first and second transverse ends 108 and 110 are all of equal length. However, it should be understood that the invention described herein is also applicable to structures having other dimensions, such as when two opposing wall components 200 are longer than the other two opposing wall components 200.

As mentioned above, the wall component 200 of the present invention may utilize a multi-layer, laminate design. In the embodiment shown in Figures 1-6, the wall component 200 utilizes a multi-layer, laminate design as shown in Figure 7 using these particular elements. The sheet metal layer 205 of the first structural layer 210 is 24 gauge galvanized steel approximately 0.022-0.028 inches thick, the foam panel 214 of the foam panel layer 213 is EPS foam approximately 5.68 inches thick, the sheet metal layer 216 of the second structural layer 215 is 24 gauge galvanized steel approximately 0.022-0.028 inches thick, and the building panel 219 of the protective layer 218 is MgO board approximately 0.25 inches (6 mm) thick.

The peripheral edges of each wall component 200 are typically provided with an outer edge reinforcement. As exemplified by the wall component 200 shown in FIG. 6, the outer edge reinforcement of the wall component 200 is a floor board 220 along the horizontal bottom edge, a ceiling board 240 along the horizontal top edge, and two end pieces 270, each secured at each vertical edge of the wall component 200. In the case of the wall component 200, the outer edge reinforcement provides areas for fastening similar areas of the abutting wall component 200, roof component 400, and floor component 300 in addition to protecting the outer edges of the foam panel material. In the embodiment shown in FIGS. 1-6, the floor board 220, ceiling board 240, and the outer edge reinforcement of the wall component 200 provided by the end pieces 270 are fabricated from laminated strand lumberboard that is 5.625 inches deep and 1.5 inches thick.
B. Partitioned wall component

2, the structure 150 has two opposing wall components 200, one of which includes a first wall portion 200s-1 and a second wall portion 200s-2, and the other of which includes a third wall portion 200s-3 and a fourth wall portion 200s-4. Each of the wall portions 200s-1, 200s-2, 200s-3, and 200s-4 has a generally rectangular planar structure. As shown in FIG. 2, the inner vertical end 192-1 of the wall portion 200s-1 is adjacent to the respective inner vertical end 192-2 of the wall portion 200s-2, and the inner vertical end 194-3 of the wall portion 200s-3 is adjacent to the respective inner vertical wall end 194-4 of the wall portion 200s-4. The inner edge reinforcement can be provided at any one or more of the vertical edges 192-1, 192-2, 194-3, and 194-4. In the embodiment shown in Figures 1-6, the inner edge reinforcement provided at the vertical edges 192-1, 192-2, 194-3, and 194-4 is made from laminated strand lumberboard that is 5.625 inches deep and 1.5 inches thick.

2, the first wall portion 200s-1 is fixed in position on the floor portion 300a proximal to the first transverse end 108, and the third wall portion 200s-3 is fixed in position on the floor portion 300a opposite the first wall portion 200s-1 and proximal to the second transverse end 110. The first wall portion 200s-1 is joined to the second wall portion 200s-2 by a hinge structure that allows the wall portion 200s-2 to pivot about a vertical axis 192 between a folded position and an unfolded position, and the third wall portion 200s-3 is joined to the fourth wall portion 200s-4 by a hinge structure that allows the fourth wall portion 200s-4 to pivot about a vertical axis 194 between a folded position and an unfolded position.

In particular, the first wall portion 200s-1 is longer than the third wall portion 200s-3 by a distance approximately equal to the thickness of the wall component 200, and the second wall portion 200s-2 is shorter than the fourth wall portion 200s-4 by a distance approximately equal to the thickness of the wall component 200. Furthermore, the wall portions 200s-1 and 200s-3 each have a length (transverse dimension) less than the transverse dimension of the floor portion 300a. Dimensioning the lengths of the wall portions 200s-1, 200s-2, 200s-3, and 200s-4 in this manner allows the wall portions 200s-2 and 200s-4 to overlap or nest relative to one another in an overlapping relationship when in the inwardly folded position. In this regard, Figure 2 shows both wall portions 200s-2 and 200s-4 in an unfolded position, labeled 200s-2u and 200s4-u, respectively, and Figure 2 also shows both wall portions 200s-2 and 200s-4 in an inwardly folded position, labeled 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 deployed position (200s-2u), it forms, together with wall portion 200s-1, a wall component 200 adjacent to the first transverse end 108, and when wall portion 200s-4 is in its deployed position (200s-4u), it forms, together with wall portion 200s-3, a wall component 200 adjacent to the second transverse end 110.

The hinge structures referenced above may be surface mounted or recessed and may be temporarily or permanently secured to secure the first wall portion 200b-1 to the second wall portion 200b-2 and the third wall portion 200s-3 to the fourth wall portion 200s-4. Reinforcement of the inner ends as described above may provide areas for securing such hinge structures. Suitable hinge structures may be made of, for example, ferrous or non-ferrous metals, plastics or leather materials.
C. Undivided wall components

The two wall components 200 adjacent the first and second transverse ends 108 and 110 are partitioned into wall sections, whereas the remaining two wall components 200 adjacent the first and second longitudinal ends 106 and 116 do not constitute multiple wall sections, but rather each have a single piece structure. However, one of these wall components 200, sometimes referred to as 200P in this disclosure, is located on the floor section 300b adjacent the first longitudinal end 106 and is pivotally fixed to the floor section 300b by a hinge structure. This allows the wall component 200P to pivot about the horizontal axis 105 shown in FIG. 3 from a folded position to an unfolded position. Pivotally fixing the wall component 200P also facilitates the formation of a compact shipping module 100. The remaining wall component 200, sometimes referred to in this disclosure as 200R, is rigidly secured on the floor portion 300a adjacent the second longitudinal end 116 and adjacent the vertical ends of the first wall portion 200s-1 and the third wall portion 200s-3 adjacent the second longitudinal end 116, as shown in FIG. 2.

The hinge structures described above that secure the wall component 200P to the floor section 300b can be surface mounted or recessed and can be temporary or permanent. The provision of outer edge reinforcements as described above can provide an area for fastening such hinge structures. Suitable hinge structures can be made of ferrous or non-ferrous metals, plastics or leather materials, for example.
Floor Component (300)

Typically, a structure 150 utilizes one floor component 300 , and thus, the floor component 300 is usually the entire floor of the structure 150 .
A. Overview

The wall component 300 has a generally rectangular peripheral edge. Figures 4 and 5 show a floor component 300 according to the present invention. The peripheral edge of the floor component 300 is defined by a first longitudinal floor edge 117, a first transverse floor edge 120, a second longitudinal floor edge 119 and a second transverse floor edge 118. In particular, (a) the first longitudinal floor edge 117, (b) the first transverse floor edge 120, (c) the second longitudinal floor edge 119 and (d) the second transverse floor edge 118 generally coincide with (i.e., underlie) the (w) first longitudinal edge 106, (x) the first transverse edge 108, (y) the second longitudinal edge 116 and (z) the second transverse edge 110 of the finished structure 150, respectively.

The length and width of the floor component 300 can vary according to design preferences. In the particular embodiment of the structure 150 shown in Figures 2, 4 and 5, the floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).

The floor component 300 and its components are generally designed and sized in thickness and otherwise to accommodate or withstand the particular loads that the floor component 300 may be subjected to. The floor component 300 preferably utilizes a multi-layer, laminate design as described in connection with FIG. 7. In the embodiment shown in FIGS. 4 and 5, the bottom surface of the floor component 300 is constructed from a sheet metal layer 205 of the first structural layer 210, which is 24 gauge galvanized steel approximately 0.022-0.028 inches thick. Above the sheet metal layer 205 is a foam panel 214 of the foam panel layer 213. In the embodiment shown in FIGS. 4 and 5, the foam panel 214 is EPS foam approximately 7.125 inches thick. Above the foam panel layer 213 is a sheet metal layer 216 of the second structural layer 215, which is 24 gauge galvanized steel approximately 0.022-0.028 inches thick. A building panel 219 of the protective layer 218 is provided on top of the sheet metal layer 216 of the second structural layer 215, the building panel 219 being an MgO plate approximately 0.25 inches (6 mm) thick.

The periphery of each floor component 300 is typically provided with an outer edge reinforcement, as shown in Figures 4 and 5, in which a first footing beam 320 (end shown in Figure 4) is arranged at the first longitudinal floor end 117 of the floor component 300, a second footing beam 320 (end shown in Figure 5) is arranged at the second transverse floor end 118 of the floor component 300, a third footing beam 320 (end shown in Figure 5) is arranged at the first transverse floor end 120 of the floor component 300, and a fourth footing beam 320 (end shown in Figure 4) is arranged at the second longitudinal floor end 119 of the floor component 300. In the case of floor component 300, the outer edge reinforcement provided by building beams 320, in addition to protecting the edges of the foam panel material of foam panel layer 213, also helps resist vertical loads and transfer such loads to the underlying roof component 400 and the underlying wall component 200 and/or to the foundation of structure 150. In the embodiment shown in Figures 1-6, the outer edge reinforcement provided by building beams 420 of floor component 300 is made from 7.125 inch deep, 1.5 inch thick laminated strand lumberboard.
B. Floor partitions

The floor component 300 is divided into floor section 300a and floor section 300b. Figure 2 shows floor sections 300a and 300b in plan view, and Figure 4 shows floor sections 300a and 300b in cross-sectional end view.

Each of floor sections 300a and 300b is a planar, generally rectangular structure, with floor section 300a adjacent to floor section 300b. As shown in FIG. 4, inner end 301a of floor section 300a abuts inner end 301b of floor section 300b. As inner end reinforcement, floor section 300a has a reinforcement board 307 disposed adjacent to inner end 301a, and floor section 300b has a reinforcement board disposed adjacent to inner end 301b. In the embodiment shown in FIGS. 1-6, the inner end reinforcement provided by reinforcement board 307 is a 7.125 inch deep, 1.5 inch thick laminated strand lumber board.

With reference to the structure 150 shown in Figures 2 and 4, the floor component 300a is fixed relative to the first wall section 200s-1, the third wall section 200s-3 and the wall component 200s-R. The floor section 300a is joined to the floor section 300b by a hinge structure such that the floor section 300b can pivot about a horizontal axis 305 located adjacent the top surface of the floor component 300 through an arc of approximately ninety degrees (90°) between a fully folded position in which the floor section 300b is oriented vertically as shown in Figure 3 and a fully unfolded position in which the floor section 300b is oriented horizontally and is flush with the floor section 300a as shown in Figures 2 and 4. A specific embodiment of a suitable hinge structure for joining the floor section 300a to the floor section 300b is described below.
C. Hinged vertical load transfer components

8A shows a beam assembly 325 that can be placed in the floor component 300 to provide reinforcement in the direction along the beam and to help transfer vertical loads borne by the floor component 300 to its ends. The beam assembly 325 includes two I-beams 326a and 326b. The I-beam 326a is located approximately in the center of the floor section 300a, and the I-beam 326b is located approximately in the center of the floor section 300b, each of the I-beams 326a and 326b facing in a transverse direction. A hinge assembly 329a connects the I-beams 326a and 326b. The hinge assembly 329A allows the beam assembly 325 to be folded into a beam-folded position shown in FIG. 8B and deployed into a beam-deployed position shown in FIG. 8A. Additionally, the hinge assembly 329A can be locked when the beam assembly 325 is in the beam-deployed position, which causes the beam assembly 325 to transform into a rigid structure that reinforces the floor component 300 in a direction perpendicular to its folding axis.

The hinge assembly 329A is formed from two identical hinge assembly parts 330A that are combined to form a pivot joint, as shown in Figures 8A and 8B. A detailed description of the structure of the hinge assembly 329A and its hinge assembly parts 330A is described in U.S. Non-Provisional Patent Application No. 17/527,520, entitled "Folding Beam Systems," filed on November 16, 2021, and having the same inventor as the present application. The contents of U.S. Non-Provisional Patent Application No. 17/527,520, entitled "Folding Beam Systems," filed on November 16, 2021, and having the same inventor as the present application, in particular the description of the structure of the hinge assembly 329A and its hinge assembly parts 330A described, for example, in paragraphs 0075-0087 and Figures 9-12 and 13C-13E thereof, are incorporated by reference as if fully set forth herein.

In the embodiment of the floor component 300 utilized in the structure 150 of Figures 1-5, the I-beam assembly 325 is located at a midpoint between the first transverse floor end 120 and the second transverse floor end 118, and the hinge assembly 329A is not utilized elsewhere in the floor component 300, such as adjacent the first transverse floor end 120 and the second transverse floor end 118. Thus, to aid in the smooth rotation of the floor section 300b, a first floor end hinge assembly 345A joining the floor sections 300a and 300b is provided adjacent the first transverse floor end 120, and a second floor end hinge assembly 345A joining the floor sections 300a and 300b is provided adjacent the second transverse floor end 118. The locations of both the first and second floor end hinge assemblies 345A are shown in Figure 9C. The floor end hinge assembly 345A is formed from two identical floor end hinge portions 350A (not shown in the figure). A description of the structure of the floor end hinge assembly 345A and its floor end hinge portions 350A is described in U.S. non-provisional patent application Ser. No. 17/527,520, entitled "Folding Beam Systems," filed on Nov. 16, 2021, and having the same inventor as the present application. The contents of U.S. non-provisional patent application Ser. No. 17/527,520, entitled "Folding Beam Systems," filed on Nov. 16, 2021, and having the same inventor as the present application, are incorporated by reference as if fully set forth herein, and in particular the description of the structure of the floor end hinge assembly 345A and its floor end hinge portions 350A, for example, described in paragraphs 0090-0093 and in Figures 14A-14B thereof, are incorporated by reference as if fully set forth herein.
D. Integrated floor lift structure

Optionally, the floor section 300a may be provided with structure to facilitate movement of the shipping module 100. In particular, FIG. 9A shows two fork tubes 360a, 360b, which are spaced apart or elongated members oriented transversely within the floor section 300a, as shown, for example, in FIG. 9B. The fork tubes 360a, 360b sandwich an I-beam 326a therebetween, which assists in the transfer of vertical loads to the fourth building beam 320 adjacent the second longitudinal floor end 119, as shown, for example, in FIG. 9B, and to the reinforcement board 307 disposed within the floor section 300a adjacent the inner end 301a, as shown, for example, in FIG. 9C. The hinge assembly 329A helps to further transfer those vertical loads to the I-beam 326b located in the floor section 300b, and then to the second building beam 320 adjacent to the first longitudinal floor end 117. The specific contents of the I-beams 326a, 326b and the hinge assembly 329A are disclosed in U.S. Provisional Patent Application No. 63/188,101, filed May 13, 2021, entitled "Folding Beam Systems," and having the same inventor as the present application. The contents of U.S. Provisional Patent Application No. 63/188,101, filed May 13, 2021, entitled "Folding Beam Systems," and having the same inventor as the present application, are incorporated by reference as if fully set forth herein, and in particular the description of the beam and hinge assemblies described, for example, in paragraphs 0073-0087 and in Figures 8A-13B thereof, are incorporated by reference as if fully set forth herein. The fork tubes 360a, 360b in the embodiment shown herein have a rectangular cross section and are made of, for example, steel. The specific contents of the I-beams 326a, 326b and the hinge assembly 329a are also described in U.S. Non-Provisional Patent Application No. 17/527,520, filed on November 16, 2021, and having the same inventor as the present application, as mentioned above. The contents of U.S. Non-Provisional Patent Application No. 17/527,520, filed on November 16, 2021, and having the same inventor as the present application, in particular the description of the I-beams 326a, 326b and the hinge assembly 329a described, for example, in paragraphs 0074-0089 and Figures 8A-13E, are also incorporated by reference as if fully described herein.

9B shows the arrangement of the fork tubes 360a, 360b within the structure of the floor section 300a. Each fork tube 360a, 360b rests on or is partially defined by the sheet metal layer 205, and a channel is provided in the foam panel 214 (not shown in FIG. 9) to accommodate the fork tube. The fork tubes 360a, 360b have a length sufficient to span the distance between the second longitudinal floor end 119 and the inner end 301a of the floor section 300a, and therefore present a rectangular opening 362 at each of these two ends. In this regard, the fourth building beam 320 adjacent to the second longitudinal floor end 119, and the reinforcing board 307 arranged in the floor section 300a adjacent to the inner end 301a, as shown in FIG. 9B, are provided with cutouts (not shown) to allow the fork tubes 360a, 360b to pass through the building beam 320 and the reinforcing board 307. Similarly, the I-beam end cap 221 (e.g., as shown in FIG. 10) located adjacent to the second longitudinal floor end 119 and the I-beam interlock 251 (e.g., as shown in FIG. 14 and FIG. 21A) located adjacent to the inner end 301a are provided with notches (not shown) to allow the fork tubes 360a, 360b to pass through the I-beam end cap 221 and the I-beam interlock 251.

9A-B, there is provided a fork tube plate 361a positioned relative to the fourth building beam 320, and a fork tube plate 361b positioned relative to the fourth building beam 320. The fork tube plate 361a generally spans the longitudinal distance between the I-beam 326a and the fork tube 360a, and extends longitudinally beyond the fork tube 360a toward the first transverse floor end 120. Similarly, the fork tube plate 361b generally spans the longitudinal distance between the I-beam 326a and the fork tube 360b, and extends longitudinally beyond the fork tube 360b toward the second transverse floor end 118.

Similarly, a fork tube plate 361c (shown in FIG. 9A) is provided that is positioned against the reinforcement board 307 in the floor portion 300a adjacent to the inner end 301a, and a fork tube plate 361d (visible in FIG. 9A) is provided that is positioned against the reinforcement board 307 in the floor portion 300a adjacent to the inner end 301a. The fork tube plate 361c spans approximately the longitudinal distance between the I-beam 326a and the fork tube 360a and extends longitudinally beyond the fork tube 360a toward the first transverse floor end 120. Similarly, the fork tube plate 361d spans approximately the longitudinal distance between the I-beam 326a and the fork tube 360b and extends longitudinally beyond the fork tube 360b toward the second transverse floor end 118. The fork tube plates 361a, 361b, 361c and 361d in the illustrated embodiment are made of, for example, steel.

Fork tube plates 361a and 361b can be secured to the fourth building beam 320 with adhesive and/or fasteners such as screws, and fork tube plates 361c and 361d can be secured to the reinforcement board 307 in the floor portion 300a adjacent the inner end 301a with adhesive and/or fasteners such as screws. Furthermore, fork tube plates 361a and 361c can be secured to fork tube 360a, and fork tube plates 361b and 361d can be secured to fork tube 360b, in each case for example using fasteners or welding.

The use of fork tubes 360a, 360b in moving the shipping module 100 will now be described.
Roof Component (400)

Typically, a structure 150 utilizes one roof component 400 , and thus the roof component 400 is generally the complete roof of the structure 150 .
A. Overview

The roof component 400 has a generally rectangular perimeter. Figures 1, 4 and 5 show a roof component 400 according to the present invention. The perimeter of the roof component 400 is defined by a first longitudinal roof edge 406, a first transverse roof edge 408, a second longitudinal roof edge 416 and a second transverse roof edge 410. In particular, the (a) first longitudinal roof edge 406, (b) first transverse roof edge 408, (c) second longitudinal roof edge 416 and (d) second transverse roof edge 410 of the roof component 400 generally coincide (i.e., overlap) with the (w) first longitudinal edge 106, (x) first transverse edge 108, (y) second longitudinal edge 116 and (z) second transverse edge 110 of the structure 150, respectively.

The length and width of the roof component 400 can vary according to design preferences. In the particular embodiment of the structure 150 shown in Figures 1, 4 and 5, the length and width of the roof component 400 are approximately similar to the length and width of the floor component 300.

The roof component 400 and its components are generally designed and sized in thickness and otherwise to accommodate the particular loads that the roof component 400 may be subjected to. The roof component 400 preferably utilizes a multi-layer, laminate design as described in connection with FIG. 7. In the embodiment shown in FIGS. 4 and 5, the top surface of the roof component 400 is formed of a sheet metal layer 205 of the first structural layer 210, which is 24-gauge galvanized steel having a thickness of about 0.022-0.028 inches. Beneath the sheet metal layer 205 is a foam panel 214 of the foam panel layer 213, which in the embodiment shown in FIGS. 4 and 5 is, for example, EPS foam having a thickness of about 7.125 inches. Beneath the foam panel layer 213 is a sheet metal layer 216 of the second structural layer 215, which is 24-gauge galvanized steel having a thickness of about 0.022-0.028 inches. Beneath the sheet metal layer 216 of the second structural layer 215 is a building panel 219 of the protective layer 218, which is an MgO plate approximately 0.25 inches (6 mm) thick.

An outer edge reinforcement is generally provided around the periphery of the roof component 400. For the embodiment of the roof component 400 shown in Figures 4 and 5, the outer edge reinforcement includes a first shoulder beam 435 (shown at its end in Figure 4) located at the first longitudinal roof edge 406 of the roof component 400, a second shoulder beam 435 (shown at its end in Figure 5) located at the first transverse roof edge 408 of the roof component 400, a third shoulder beam 435 (shown at its end in Figure 5) located at the second transverse roof edge 410 of the roof component 400, and a fourth shoulder beam 435 (shown at its end in Figure 4) located at the second longitudinal roof edge 416 of the roof component 400. In addition to protecting the outer edge of the foam panel material, the outer edge reinforcement provided by the shoulder beam 435 helps resist vertical loads and transfer such loads through the underlying wall components 200 supporting the roof component 400 to the lower floors and then to the foundation of the structure 150. Such outer edge reinforcements may also provide areas for fastening similar areas of adjacent enclosure components 155 (substrate and any overlay). The shoulder beams 435 of the roof component 400 may be fabricated from strand laminate lumberboard that is 7.125 inches deep and 1.5 inches thick.
B. Roof partition

The roof component 400 of the structure 150 is partitioned into roof sections 400a, 400b, and 400c. Figure 1 shows roof sections 400a, 400b, and 400c in a perspective view, and Figure 4 shows roof sections 400a, 400b, and 400c in a cross-sectional end view.

Each of the roof sections 400a, 400b, and 400c is a planar, generally rectangular structure, with the roof section 400a adjacent to the roof section 400b, which is adjacent to the roof section 400c. The inner end 412c of the roof component 400c is in contact with the first inner end 412b of the roof component 400b, as shown in FIG. 4. For inner end reinforcement, a reinforcing board 437 is disposed adjacent to the inner end 412c, and a reinforcing board 437 is disposed against the first inner end 412b. As shown in FIG. 4, the inner end 412a of the roof section 400a is in contact with the second inner end 412b of the roof section 400b. For inner end reinforcement, a reinforcing board 437 is disposed adjacent to the inner end 412a, and a reinforcing board 437 is disposed against the second inner end 412b. In the embodiment shown in Figures 1-5, the inner edge reinforcement provided by the reinforcement board 437 of the roof component 400 is a laminated strand lumber board that is 7.125 inches deep and 1.5 inches thick.

In the shipping module 100 shown in FIG. 3, the roof sections 400a, 400b and 400c are preferably accordion folded (stacked), with the roof component 400b stacked on top of the roof component 400a and the roof component 400c stacked on top of the roof component 400b. With reference to the structure 150 shown in FIG. 4, the roof section 400a is fixed in position relative to the first wall section 200s-1, the third wall section 200s-3 and the wall component 200R. Thus, to achieve the accordion folded configuration shown in FIG. 3, the roof section 400a is joined to the roof section 400b with a hinge structure provided between the inner end 412a of the roof section 400a and the second inner end 412b of the roof section 400b. Such hinge structure allows roof portion 400b to pivot in an arc of up to one hundred eighty degrees (180°) about a horizontal axis 405a, shown in Figure 4, disposed adjacent the top of roof component 400, between a fully folded roof position, shown in Figure 3, with roof portion 400b stacked flat against roof portion 400a, and a fully deployed position, shown in Figure 4. Roof portion 400b is then joined to roof portion 400c by a hinge structure disposed between a first inner end 412b of roof portion 400b and an inner end 412c of roof portion 400c. Such hinge structure allows roof portion 400c to pivot about a horizontal axis 405b, shown in FIG. 4 as being disposed adjacent the bottom of roof component 400, through an arc of up to one hundred and eighty degrees (180°) between a folded position shown in FIG. 3, with roof portion 400c stacked flat against roof portion 400b (when roof portion 400b is stacked flat against roof portion 400a), and a fully deployed position shown in FIG. 4.

Particular embodiments of structural components that also incorporate hinge structures suitable for joining roof portion 400a to roof portion 400b and roof portion 400b to roof portion 400c are described in U.S. Non-Provisional Patent Application No. 17/527,520, entitled "Folding Beam Systems," filed November 16, 2021, and having the same inventor as the present disclosure. The contents of U.S. Non-Provisional Patent Application No. 17/527,520, filed November 16, 2021, and having the same inventor as the present disclosure, are incorporated by reference as if fully set forth herein, particularly the description of the load transfer components set forth, for example, in paragraphs 0104-0126 and Figures 15A-24A thereof, and the description of the associated end hinge assemblies set forth, for example, in paragraphs 0127-0132 and Figures 24B and 25A-25D thereof.
Housing Component Seal Systems

The structure 150 may utilize an enclosure component sealing system, described below, to limit or prevent the ingress of rainwater, noise, and outside air into the interior of the structure 150 .
A. Overview

The housing component seal system of the structure 150 utilizes the seal structure described below. With the exception of the I-beam end caps 221, which function to seal or seal the ends of selected housing components 155, the housing component seal system generally consists of two housing component seal structures that are pressed into contact in different combinations to seal the joints between different areas of the housing components 155 found in the structure 150. These joints are either the two inner ends of adjacent housing component portions that are end-to-end when the structure 150 is deployed, or the outer ends of the housing components 155 that are in contact with the inner surface of another housing component 155. When the housing component seal structure is positioned at the inner or outer ends of the housing components 155. When the multi-layer, laminate design shown in FIG. 7 is utilized (such as when the housing component seal structure is positioned adjacent to the inner or outer ends of the foam panel layer 213), inner or outer end reinforcements can be provided between the seal structure and the respective inner or outer ends of the foam panel layer 213. The specific housing component seal structures described below are I-beam end cap 221, wall vertical interlock 245, wall end cap 246, I-beam interlock A 250, I-beam interlock B 251, floor top plate 252, roof bottom plate 255, floor top interlock 261, wall end interlock A 262, and wall end interlock B 263. With the exception of I-beam end cap 221, each of the housing component seal structures described above utilizes either two or more compression seals 230 or a shear seal 260, which are also described below. Exemplary arrangements of the housing component seal structures described herein are described below in subsections B. through J. and also in the section below entitled "Exemplary Arrangements of Housing Component Seal Structures."

The present invention includes two closure boards: a perimeter board 310 and a roof skirt board 280. These closure boards, described below, are utilized in combination with the I-beam end caps 221 to provide additional sealing and achieve additional benefits.
B. I-beam end cap (221)

The I-beam end cap 221, shown in cross section in FIG. 10, is a rigid, elongated member that is secured to the periphery of a selected housing component 155, preferably the outer ends of the floor component 300 and roof component 400. The I-beam end cap 221 provides an end seal that seals the end of the housing component 155 to which it is secured against water ingress and environmental exposure, and provides impact resistance to the end.

10 shows an exemplary installation of an I-beam end cap 221 secured to the end of a schematic diagram of floor section 300a. In particular, the I-beam end cap 221 has an elongated seal plate 223 having an elongated inner surface 226 and an opposing elongated planar outer surface 227. The I-beam end cap 221 has a length and width that are the same or substantially the same as the length and width of the outer end of floor section 300a so as to cover all or substantially all of the outer end of floor section 300a.

At the midpoint of the inner surface 226 of the seal plate 223 is provided an elongated key 222 that is rectangular in cross section (as shown in FIG. 10) and has a length equal to or substantially equal to the length of the I-beam end cap 221. The key 222 is received in a corresponding slot formed in an outer end reinforcement disposed at the outer end of the housing component 155 to which the I-beam end cap 221 is secured. Thus, for example, FIG. 9 shows the key 222 of the I-beam end cap 221 received in a slot 422 in the shoulder beam 435 of the roof section 400a. Each of the upper and lower ends of the I-beam end cap 221 defines a locating slot 229. If the housing component 155 utilizes the housing component stacking design shown in FIG. 7, the locating slot 229 receives the ends 207 of the metal sheets 206 and 217 (of the sheet metal layers 205 and 216, respectively) that are bent at a ninety degree (90°) angle, as shown in FIG. 9.

10, the outer surface 227 of the seal plate 223 of the I-beam end cap 221 includes an elongated attachment slot 224 that is rectangular in cross section and has a length that is the same as or substantially the same as the length of the outer surface 227 of the I-beam end cap 221. The outer surface 227 further includes a plurality of elongated fastener locating grooves 225, each having a length that is the same as or substantially the same as the length of the seal plate 223. The I-beam end cap 221 may be secured to an outer end of a housing component 155, such as the roof section 400a shown in FIG. 9 and the floor section 300a shown in FIG. 10, by, for example, an adhesive applied to the inner surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the I-beam end cap 221 and driven through the outer wall surface 227, or by utilizing a combination of adhesive and fasteners. The locating grooves 225 aid in accurate positioning of such fasteners.
C. Compression Seal (230)

A number of housing component seal systems described herein and utilized in structure 150 include a compression seal system. An element of that compression seal system is compression seal 230.

11A, the compression seal 230 is an elongated member having an elongated base 231 in cross section, with an elongated arched portion 232 flanked by two elongated winglets 233. At the intersection of the arched portion 232 of the base 231 with each of the winglets 233, there are two opposing elongated seal walls 234 joined to the base 231 and in a diverging relationship extending away from the base 231 at a diverging angle θ, θ<180°, e.g., θ<90°, or 40°<θ<50°. Most preferably, θ is the same as or close to the diverging angle ε of the slot wall 244 described below. Thus, as shown in FIG. 11A, the ends of the seal wall 234 distal from the base 231 are spaced apart from the ends of the seal wall proximate to the base 231.

At the ends of the seal walls 234 distal from the base 231, each seal wall 234 is joined to an elongated arcuate buttress 235. The ends of each arcuate buttress 235 distal from the seal wall 234 to which it is joined are then joined to a respective elongated planar seal surface 236, so that there are two planar seal surfaces 236 in the compression seal 230. The planar seal surfaces 236 have a converging relationship extending away from the seal wall 234 at a convergent angle δ, δ<180°, e.g., 90°. Thus, the ends of the seal surfaces 236 distal from the arcuate buttress 235 are closer together than the ends of the seal surfaces 236 proximate to the arcuate buttress 235. The ends of the seal surfaces 236 distal from the arcuate buttress 235 are joined by an elongated seal closure 237. The base 231, the seal wall 234, the arcuate buttress 235, the seal surface 236, and the seal closure portion 237 define a hollow, elongated seal chamber 238, as shown in FIG. 11A. The seal closure portion 237 curves toward the seal chamber 238 to provide a cup-like appearance.

The compression seal 230 is intended to be received in an elongated seal slot 240, for example as shown in FIG. 11B. The slot 240 has a generally dovetail shape with an elongated planar floor 241 sandwiched between two elongated transverse grooves 242, with an elongated planar slot wall 244 extending from each groove 242 toward and tangentially to an elongated shoulder 243 in the surface of the slot 240. Thus, the seal slot 240 has two opposing shoulders 243. The planar slot wall 244 has a diverging relationship extending away from the groove 242 at a diverging angle ε, where ε<180° (e.g., ε<90°, or within the range of 40°<ε<50°), such that the end of the slot wall 244 coinciding with the shoulder 243 is farther away than the end of the slot wall 244 adjacent to the groove 242. The compression seal 230 is sized to sealingly fit within the slot 240, as shown in FIG. 11B, such that the winglets 233 are received within the grooves 242 and the arched portion 232 of the base 231 is sufficiently compressed to provide a resilient force that presses the winglets 233 into the grooves 242 and holds the compression seal 230 in place within the slot 240 during and after manufacture of the housing component 155.

When the two paired housing component seal structures, one of which carries a compression seal 230, are attached to the two housing components 155 and the housing components 155 are properly positioned and pressed together, the compression seal 230 presses against the planar outer surface 227 of the opposing seal plate 223, which causes the seal closure portion 237 and the arcuate buttress 235 to move into the seal chamber 238. This brings the two planar outer surfaces 227 of the pressed seal plates 223 of the paired seal structures into full contact. At the same time, the arcuate buttress 235 rotates down and the seal surface 236 presses against the opposing planar outer surface 227 (with the arcuate buttress 238 acting as a hinge) into a generally coplanar relationship, forming two seal lines.

The compression seal 230 may be made from a resilient material such as rubber or plastic, e.g., polyurethane, etc. Specific embodiments of housing component seal structures utilizing the compression seal system described above are described below.
D. Wall Vertical Interlock (245), Wall End Cap (246) Seal System

FIG. 12 shows an exploded view of the joint between the wall vertical interlock 245 and the wall end cap 246. The particular joint is shown for illustrative purposes between wall sections 200s-1 and 200s-2, with the wall vertical interlock 245 located on the inner vertical end of wall section 200s-2 (inner vertical end 192-2 shown in FIG. 2) and the wall end cap 246 located on the inner vertical end of wall section 200s-1 (inner vertical end 192-1 shown in FIG. 2). In the structure 150, the wall vertical interlock 245 and the wall end cap 246 shown in FIG. 12 are vertically oriented.

In particular, wall vertical interlock 245 is a rigid elongated member having an elongated seal plate 223 with an elongated inner surface 226 and an opposing elongated planar outer surface 227. Outer surface 227 is preferably hard and smooth to provide a good sealing surface. Seal plate 223 has a length and width that are the same or substantially the same as the length and width of the inner end of wall portion 200s-2 so as to cover all or substantially all of that inner end of wall portion 200s-2.

12, the wall vertical interlock 245 is provided at its midpoint on its inner surface 226 with an elongated key 222 that is rectangular in cross section and has a length equal to or substantially equal to the length of the seal plate 223. The key 222 is received in a corresponding elongated slot formed in an inner edge reinforcement disposed at the inner vertical edge of the wall section 200s-2 to which the wall vertical interlock 245 is fixed. Each of the upper and lower edges of the wall vertical interlock 245 defines an elongated locating slot 229 for receiving the ends of the sheet metal layers 205 and 216 when folded at a ninety degree (90°) angle. Additionally, one end of the slot 229 that abuts the inner surface 226 of the wall vertical interlock 245 terminates an insertion distance "I" away from the opposite end of the slot, where I is the thickness of the protective layer 218, such as a magnesium oxide (MgO) plate.

12, the wall vertical interlock 245 has an elongated interlock slot 228 at the midpoint of the outer surface 227 of the seal plate 223, the interlock slot 228 being rectangular in cross section and having a length equal to or substantially equal to the length of the outer surface 227 of the wall vertical interlock 245. As shown in FIG. 12, two elongated seal slots 240 are defined on the outer surface 227 of the wall vertical interlock 245, one above the interlock slot 228 and the other below the interlock slot 228. Each slot 240 has a length equal to or substantially equal to the length of the wall vertical interlock 245.

The wall vertical interlock 245 can be secured to the vertical end of the wall section 200s-2 shown in FIG. 12, for example, by adhesive applied to the inner surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the wall vertical interlock 245 and driven through the outer wall surface 227, or by utilizing a combination of adhesive and fasteners.

12 also shows wall end cap 246. Wall end cap 246 shown in FIG. 12 is a rigid elongated member defined by elongated seal plate 223 having elongated inner surface 226 and opposing elongated planar outer surface 227. Outer surface 227 is preferably hard and smooth to provide a good sealing surface. Seal plate 223 has the same or substantially the same length and width as the outer end of wall portion 200s-1, and is adapted to cover all or substantially all of the vertical end of wall portion 200s-1 shown in FIG. 12.

12, the wall end cap 246 is provided at its midpoint with an elongated inner surface 226 that is rectangular in cross section and has a length equal to or substantially equal to the length of the seal plate 223. The key 222 of the wall end cap 246 is received in a corresponding elongated slot formed in an inner end reinforcement disposed at the vertical inner end of the wall section 200s-1 to which the wall end cap 246 is fixed. Each of the upper and lower edges of the wall end cap 246 defines an elongated locating slot 229 for receiving the ends of the sheet metal layers 205 and 216 when folded at a ninety degree (90°) angle. Furthermore, one end of the slot 229 that abuts the inner surface 226 of the wall end cap 246 terminates at an insertion distance "I" from the opposite end of the slot, where I is the thickness of a protective layer 218, such as a magnesium oxide (MgO) plate.

The wall end cap 246 can be secured to the vertical end of the wall section 200s-1 shown in FIG. 12 by, for example, an adhesive applied to the inner surface 226, or by fasteners, such as screws or nail fasteners, spaced along the length of the wall end cap 246 and driven through the outer wall surface 227, or by utilizing a combination of adhesive and fasteners.

12, the wall vertical interlock 245 fits with the wall end cap 246. For this purpose, at the midpoint of the outer surface 227 of the seal plate 223 of the wall end cap 246, an elongated interlock key 247 is provided, which is rectangular in cross section and has a length equal to or substantially equal to the length of the outer surface 227 of the wall end cap 246. The interlock key 247 fits with the interlock slot 228 when the wall vertical interlock 245 and the wall end cap 246 are pressed together. Furthermore, the two ends of the wall end cap 246 are provided with elongated coupling ridges (or bumps) 248 that fit with elongated coupling insets 249 located at the ends of the wall vertical interlock 245. The coupling ridges 248 and the coupling insets 249 can have the same length or approximately the same length as the wall end cap 246 and the wall vertical interlock 245, respectively.

Prior to mating the wall vertical interlock 245 with the wall end cap 246, a compression seal 230 is placed in each of the two seal slots 240 of the wall vertical interlock 245, with each seal 230 having the same or approximately the same length as the slot 240 into which it is inserted. When the wall vertical interlock 245 and the wall end cap 246 are pressed together in mating relationship, the two compression seals 230 deform in the manner previously described to provide four seal lines between the wall vertical interlock 245 and the wall end cap 246.
E. I-Beam Interlock A (250), I-Beam Interlock B (251) Seal System

FIG. 14 shows an exploded view of the joint between I-beam interlock A250 and I-beam interlock B251, each shown in cross section. The particular joint is shown for illustrative purposes between roof section 400b and roof section 400c, with I-beam interlock A250 located on the inner edge 412c of roof section 400c and I-beam interlock B251 located on the first inner edge 412b of roof section 400b. In structure 150, I-beam interlock A250 and I-beam interlock B251 shown in FIG. 14 are oriented horizontally.

In particular, the I-beam interlock A250 is a rigid elongated member defined by an elongated seal plate 223 having an elongated inner surface 226 and an opposing elongated planar outer surface 227. The outer surface 227 is preferably hard and smooth to provide a good sealing surface. The seal plate 223 has a length and width that is the same as, or substantially the same as, the length and width of the inner end 412c of the roof section 400c shown in FIG. 14, and is adapted to cover the entirety or substantially the entirety of that inner end.

14, the I-beam interlock A250 is provided at its midpoint with an elongated key 222 having a rectangular cross section and a length equal to or substantially equal to the length of the I-beam interlock A250. The key 222 is received in a corresponding elongated slot formed in an inner end reinforcement disposed at the horizontal end of the roof section 400c to which the I-beam interlock A250 is secured. Each of the upper and lower ends of the I-beam interlock A250 defines an elongated locating slot 229 for receiving the ends of the sheet metal layers 205 and 216 bent at a ninety degree (90°) angle. Additionally, one end of the slot 229 abutting the inner end surface 226 of the I-beam interlock A250 terminates at an insertion distance "I" from the opposite end of the slot, where I is the thickness of the protective layer 218, such as a magnesium oxide (MgO) plate.

Referring further to FIG. 14, the lower half of the outer surface 227 of the seal plate 223 of the I-beam interlock A250 is provided with an elongated interlock slot 228 having a rectangular cross-section and a length equal to or substantially equal to the length of the outer surface 227 of the I-beam interlock A250. The outer surface 227 of the I-beam interlock A250 defines three elongated seal slots 240, two above the interlock slot 228 and one below the interlock slot 228, as shown in FIG. 14. Each seal slot 240 has a length equal to or substantially equal to the length of the I-beam interlock A250.

The I-beam interlock A250 can be secured to the inner end 412c of the roof section 400c shown in FIG. 14, for example, by adhesive applied to the inner surface 226, or by fasteners, such as screws or nail fasteners, spaced along the length of the I-beam interlock A250 and driven through the outer wall surface 227, or by utilizing a combination of adhesive and fasteners.

14 further illustrates the I-beam interlock B251. The I-beam interlock B251 is a rigid elongated member defined by an elongated seal plate 223 having an elongated inner surface 226 and an opposing elongated planar outer surface 227. The outer surface 227 is preferably hard and smooth to provide a good sealing surface. The seal plate 223 has a length and width that is the same as or substantially the same as the length and width of the first inner end 412b of the roof portion 400b, and is adapted to cover the entirety or substantially the entirety of that inner end.

14, the elongated inner surface 226 of the I-beam interlock B251 is provided at its midpoint with an elongated key 222 having a rectangular cross section and a length equal to or substantially equal to the length of the I-beam interlock B251. The key 222 of the I-beam interlock B251 is received in a corresponding elongated slot formed in an outer end reinforcement disposed at the first inner end 412b of the roof section 400b to which the I-beam interlock B251 is secured. Each of the upper and lower ends of the I-beam interlock B251 defines an elongated locating slot 229 for receiving the ends of the sheet metal layers 205 and 216 bent at a ninety degree (90°) angle. Additionally, one end of the slot 229 abutting the inner end surface 226 of the wall end cap 246 terminates at an insertion distance "I" from the opposite end of the slot, where I is the thickness of the protective layer 218, such as a magnesium oxide (MgO) plate.

The I-beam interlock B251 can be secured to the first inner end 412b of the roof portion 400b, for example, by adhesive applied to the inner surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the I-beam interlock B251 and driven through the outer wall surface 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 14, the I-beam interlock A 250 mates with the I-beam interlock B 251. For this purpose, the lower half of the outer surface 227 of the seal plate 223 of the I-beam interlock B 251 is provided with an elongated interlock key 247 having a rectangular cross section and having a length equal to or substantially equal to the length of the I-beam interlock B 251. The interlock key 247 fits into the interlock slot 228 when the I-beam interlock A 250 and the I-beam interlock B 251 are pressed against each other. Furthermore, the outer end of the I-beam interlock B 251 is provided with an elongated coupling ridge 248, which mates with an elongated coupling inset 249 located at the outer end of the I-beam interlock A 250. The coupling ridge 248 and the coupling inset 249 can have the same length or approximately the same length as the I-beam interlock A 250 and the I-beam interlock B 251, respectively.

Prior to mating I-beam interlock A 250 with I-beam interlock B 251, a compression seal 230 is placed in each of the three seal slots 240 of I-beam interlock A 250, with each seal 230 having the same or approximately the same length as the slot 240 into which it is inserted. When I-beam interlock A 250 and I-beam interlock B 251 are forced into mating relationship, the three compression seals 230 deform in the manner previously described, providing six seal lines between I-beam interlock A 250 and I-beam interlock B 251.
F. Floor Top Plate (252), Wall End Cap (246) Seal System

15 shows in exploded form the joint between the floor top plate 252 and the wall end cap 246, each shown in cross section. The particular joint is shown between the wall component 200R and the floor section 300a for illustrative purposes, with the floor top plate 252 disposed along the upper surface of the floor section 300a adjacent the second longitudinal floor end 119, and the wall end cap 246 disposed at the lower end of the wall component 200R. In the structure 150, the wall 200R shown in FIG. 15 is oriented vertically and the floor section 300a is oriented horizontally.

In particular, the floor top plate 252 of FIG. 15 is a rigid elongated member having an elongated seal plate 223 having an elongated inner surface 226 and an opposing elongated planar outer surface 227. The outer surface 227 is preferably hard and smooth to provide a good sealing surface. The seal plate 223 has a length equal to or substantially equal to the length of the second longitudinal floor edge 119 so as to cover the upper end of the floor section 300a proximate the second longitudinal floor edge 119. The seal plate 223 of the floor top plate 252 has a width equal to or substantially equal to the width of the wall component 200R. The floor top plate 252 preferably has a thickness "J" sufficient to accommodate the thickness of any protective layer 218 and/or flooring material, e.g., stone, wood or carpet, used on the surface of the floor section 300a.

15, at the outer end of the elongated inner surface 226 of the floor top plate 252, adjacent the second longitudinal floor end 119, there is a series of elongated stepped locating ridges 254. These stepped locating ridges, having a length equal to or substantially equal to the length of the floor top plate 252, mate with corresponding stepped locating ridges 253 shown on the I-beam end cap 221 shown in FIG. 10 and in dashed lines in FIG. 15.

15, at the midpoint of the outer surface 227 of the seal plate 223 of the floor top plate 252, there is provided an elongated interlocking slot 228 having a rectangular cross-section and a length equal to or substantially equal to the length of the floor top plate 252. As shown in FIG. 15, there are two elongated seal slots 240 defined in the outer surface 227 of the floor top plate 252, one on each side of the interlocking slot 228. Each slot 240 has a length equal to or substantially equal to the length of the floor top plate 252.

The floor top plate 252 can be secured to the upper end of the floor section 300a adjacent the second longitudinal floor end 119 shown in FIG. 15 by, for example, an adhesive applied to the inner surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the floor top plate 252 and driven through the outer wall surface 227, or by utilizing a combination of adhesive and fasteners.

15 further illustrates a wall end cap 246 disposed along the bottom edge of the wall component 200R. The design of the wall end cap 246 is described above in connection with FIG. 12. The seal plate 223 of the wall end cap 246 shown in FIG. 15 has a length and width that is the same, or substantially the same, as the length and width of the bottom edge of the wall component 200R, so as to cover the entirety, or substantially the entirety, of the bottom edge of the wall component 200R shown in FIG. 15.

The wall end cap 246 can be secured to the lower end of the wall component 200R shown in FIG. 15 by, for example, an adhesive applied to the inner surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the wall end cap 246 and driven through the outer wall surface 227, or by utilizing a combination of adhesive and fasteners.

15, the floor top plate 252 mates with the wall end cap 246. To this end, the interlocking key 247 of the wall end cap 246 has a length that is the same as or substantially the same as the length of the outer wall surface 227 of the floor top plate 252. The interlocking key 247 mates with the interlocking slot 228 of the floor top plate 252, with the elongated coupling ridge 248 of the wall end cap 246 mating with the elongated coupling inset 249 of the floor top plate 252 when the floor top plate 252 and the wall end cap 246 are pressed together. The coupling ridge 248 and the coupling inset 249 can have the same length or approximately the same length as the wall end cap 246 and the floor top plate 252, respectively.

Prior to mating the wall end cap 246 and floor top plate 252, a compression seal 230 is placed in each of the two seal slots 240 in the floor top plate 252, with each seal 230 having the same or approximately the same length as the seal slot 240 into which it is inserted. When the wall vertical interlock 245 and wall end cap 246 are pressed together in mating relationship, the two compression seals 230 deform in the manner previously described to provide four seal lines between the wall end cap 246 and the floor top plate 252.
G. Roof bottom plate (255), wall end cap (246) seal system

13 illustrates in exploded form the joint between the roof bottom plate 255 and the wall end cap 246, each shown in cross section. The particular joint shown for illustrative purposes is between the wall component 200R and the roof portion 400a, with the roof bottom plate 255 disposed along the underside of the roof portion 400a adjacent the second longitudinal roof edge 416, and the wall end cap 246 disposed at the upper end of the wall component 200R. In the structure 150, the wall component 200R in FIG. 13 is oriented vertically and the roof portion 400a is oriented horizontally.

15 is substantially the same design as the floor top plate 252 shown in FIG. 15, but the roof bottom plate 255 is thinner since it is not necessary to accommodate the thickness of any flooring material; for example, the roof bottom plate 255 may have a thickness "I" equal to the thickness of the adjacent protective layer 218, such as an MgO board. The roof bottom plate 255 of FIG. 13 is a rigid elongated member having an elongated seal plate 223 having an elongated planar inner surface 226 and an opposing elongated planar outer surface 227. The outer surface 227 is preferably hard and smooth to provide a good sealing surface. The seal plate 223 of the roof bottom plate 255 has a length equal to or substantially equal to the length of the second longitudinal roof edge 416 so as to cover the lower end of the roof portion 400a adjacent the second longitudinal roof edge 416. The seal plate 223 of the roof bottom plate 255 has a width equal to or substantially equal to the width of the wall component 200R.

13, the outer end of the elongated inner surface 226 of the roof bottom plate 255 is provided with a series of elongated stepped locating ridges 254 adjacent the second longitudinal roof end 416. These stepped locating ridges, which have a length equal to or substantially equal to the length of the roof bottom plate 255, mate with corresponding stepped locating ridges 253 of the wall end cap 221 shown in FIG. 10 and in dashed lines in FIG. 13, and are positioned at the outer end of the roof portion 400a.

With further reference to FIG. 13, the outer surface 227 of the seal plate 223 of the roof bottom plate 255 defines an elongated interlocking slot 228 at its midpoint, the interlocking slot 228 having a rectangular cross-section and a length equal to or substantially equal to the length of the roof bottom plate 255. The outer surface 227 of the roof bottom plate 255 defines two elongated seal slots 240, one on each side of the interlocking slot 228, as shown in FIG. 13. Each seal slot 240 defines a length equal to or substantially equal to the length of the roof bottom plate 255.

The roof bottom plate 255 can be secured to the bottom surface of the roof section 400a shown in FIG. 13, for example, by adhesive applied to the inner surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the roof bottom plate 255 and driven through the outer surface 227, or by utilizing a combination of adhesive and fasteners.

13 further illustrates a wall end cap 246 disposed along the top edge of the wall component 200R. The design of the wall end cap 246 was previously described in connection with FIG. 12. The seal plate 223 of the wall end cap 246 illustrated in FIG. 13 has a length and width that are the same as, or substantially the same as, the length and width of the top edge of the wall component 200R so as to cover the entirety or substantially the entirety of the top edge of the wall component 200R. The wall end cap 246 may be secured to its top end, for example, by adhesive applied to its inner end 226, or by fasteners such as screws or nail fasteners spaced along the length of the wall end cap 246 and driven through its outer end 227, or by utilizing a combination of adhesive and fasteners.

13, the roof bottom plate 255 mates with the wall end cap 246. To this end, the interlocking key 247 of the wall end cap 246 has a length equal to or substantially equal to the length of the roof bottom plate 255. The interlocking key 247 mates with the interlocking slot 228 of the roof bottom plate 255, with the elongated coupling ridge 248 of the wall end cap 246 mating with the elongated coupling inset 249 of the roof bottom plate 255 when the roof bottom plate 255 and the wall end cap 246 are pressed together. The coupling ridge 248 and the coupling inset 249 may be equal to or substantially equal to the length of the wall end cap 246 and the roof bottom plate 255, respectively.

Prior to mating the wall end cap 246 and the roof bottom plate 255, a compression seal 230 is placed in each of the two seal slots 240 in the roof bottom plate 255, with each seal 230 having the same or approximately the same length as the slot 240 into which it is inserted. When the roof bottom plate 255 and the wall end cap 246 are pressed together in mating relationship, the two compression seals 230 deform in the manner previously described, providing four seal lines between the roof bottom plate 255 and the wall end cap 246.
H. Shear Seal (260)

A number of housing component seal systems described herein and utilized in structure 150 include a shear seal system. An element of that shear seal system is shear seal 260.

The shear seal 260, shown in cross section in FIG. 16A, is an elongated member having a planar elongated base 231, sandwiched between two elongated winglets 233. At the intersection of the base 231 and each winglet 233, there are two opposing elongated seal walls 234 (respectively referred to as seal walls 234A, 234B) joined to the base 231 and having a diverging relationship extending away from the base 231 at a diverging angle θ, λ<180°, e.g., λ<90°, or 40°<λ<50°. Most preferably, λ is the same as or close to the diverging angle ε of the slot wall 244 shown in FIG. 11B. Thus, as shown in FIG. 16A, the ends of the seal walls 234 distal to the base 231 are spaced apart from the ends of the seal walls 234 proximate to the base 231.

At the end of the seal wall 234B distal from the base 231, the seal wall 234B is joined to the elongated seal closure portion 237, with a plane that is angled upwards at an angle α (relative to the plane of the base 231) away from the seal wall 234B toward the elongated seal support 239, described below, where α<90°. A planar cantilever seal surface 257 is joined to the end of the seal closure portion 237 distal from the seal wall 234B, as shown in FIG. 16A.

At the end of the seal wall 234A distal from the base 231, the seal wall 234A is joined to an elongated seal support 239. Proximate the seal wall 234A, the seal support 239 consists of an elongated planar region oriented parallel to the base 231. Distal from the seal wall 234A, the seal support 239 includes an elongated arcuate buttress region. The end of the arcuate buttress region of the seal support 239 distal from the seal wall 234A joins the cantilevered seal surface 257 proximate the junction of the cantilevered seal surface 257 and the seal closure portion 237 to define the hollow seal chamber 238. The planar cantilevered seal surface 257 faces away from the junction of the arcuate buttress 235 and the seal closure portion 237 at an upward angle β, terminating at a free end 258, where β<90°, e.g., β>α.

The shear seal 260 has the same shape as the seal slot 40 utilized to receive the compression seal 230, and is intended to be received in the elongated seal slot 240 shown in FIG. 16B, for example. The shear seal 260 is dimensioned to be sealed within the slot 240, such that the winglets 233 of the seal 260 are received in the grooves 242 of the slot 240. An exemplary arrangement of the shear seal 260 is shown in FIG. 16B, which shows the shear seal 260 disposed within the slot 240 of the wall end interlock A 262, which will be described further below. As shown, when the shear seal 260 is properly disposed within the slot 240, both the seal wall 234A and the seal wall 234B terminate below the level of the outer surface 227 of the wall end interlock A 262, and the seal wall 234A (the underlying planar cantilever seal surface 257) terminates below the level at which the seal wall 234B terminates.

The shear seal 260 is preferably utilized when two housing components 155 are moved laterally, one over the other, during deployment. In such an example, the two housing components 155 include a pair of housing component seal structures, one housing component seal structure attached to one of the housing components 155 (such as an outer end) and the other housing component seal structure attached to the other of the housing components 155 (such as an inner wall surface). Each pair of housing component seal structures has a shear seal 260, and the two shear seals 260 are opposed, that is, the respective cantilever seal surfaces 257 face away from each other and each face in the direction of relative movement. For each of the two shear seals 260, the transverse movement of one housing component 155 relative to the other is from seal wall 234B toward seal wall 234A. This transverse movement flattens the cantilevered seal surface 257, as well as the seal closure portion 237, and seals each shear seal 260 such that its seal closure portion 237 and seal support 239 are forced into the seal chamber 238. This brings the opposing planar outer surfaces 227 of each of the two housing component seal structures into full contact. At the same time, the cantilevered seal surface 257 and seal closure portion 237 of each shear seal 260 are forced into a generally coplanar relationship such that the elongated planar outer surface 227 of the opposing housing component seal structure is forced against them to form an elongated sealed region.

The shear seal 260 may be made from a resilient material such as rubber or plastic, for example polyurethane.Specific embodiments of housing component seal structures utilizing the above-described seal systems are described below.
I. Wall End Interlock A (262), Floor Top Interlock (261) Seal System

FIG. 17 illustrates in exploded view the joint between floor top interlock 261 and wall end interlock A 262, each shown in cross section. The particular joint is shown between wall section 200s-2 and floor section 300b for illustrative purposes, with floor top interlock 261 located along the top surface of floor section 300b adjacent first transverse floor end 120, and wall end interlock A 262 located at the bottom end of wall section 200s-2. In structure 150, wall section 200s-2 in FIG. 17 is oriented vertically and floor section 300b is oriented horizontally.

In particular, the floor top interlock 261 shown in FIG. 17 is a rigid elongated member having an elongated seal plate 223 having an inner surface 226 and an opposing elongated planar outer surface 227. The outer surface 227 is preferably hard and smooth to provide a good sealing surface. The seal plate 223 has a length that is the same as or substantially the same as the dimension of the floor portion 300b that coincides with the first transverse floor edge 120 so as to cover the top edge of the floor portion 300b proximate the first transverse floor edge 120. The seal plate 223 of the floor top interlock 261 has a width that is the same as or substantially the same as the width of the wall portion 200s-2. The floor top interlock 261 preferably has a thickness "J" at its inner end as shown in FIG. 17, sufficient to accommodate the thickness of any protective layer 218 and/or flooring material used on the surface of the floor portion 300b, such as stone, wood, carpet, etc.

17, the outer end of the elongated inner surface 226 of the floor top interlock 261 is provided with a series of elongated stepped locating ridges 254 adjacent the first transverse floor end 120. These stepped locating ridges 254 have the same or substantially the same length as the floor top interlock 261 and mate with corresponding stepped locating ridges 253. This is shown in the wall end cap 221 shown in FIG. 10. Such a wall end cap 221 is located at the outer end of the wall portion 300b as shown in dashed lines in FIG. 17.

With further reference to FIG. 17, an elongated seal slot 240 is defined on the outer surface 227 of the floor top interlock 261 proximate the outer end of the floor portion 300b (such outer end coinciding with the first transverse floor end 120). The seal slot 240 has a length that is the same as or substantially the same as the length of the floor top interlock 261.

The floor top interlock 261 can be secured to the upper end of the floor section 300b at the first transverse floor end 120 shown in FIG. 17 by, for example, an adhesive applied to the inner surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the floor top interlock 261 and driven through the outer surface 227, or by utilizing a combination of adhesive and fasteners.

Wall end interlock A262, also shown in FIG. 17, is a rigid elongated member having an elongated seal plate 223 with an inner surface 226 and an opposing outer surface 227. The outer surface 227 is preferably hard and smooth to provide a good sealing surface. The seal plate 223 of wall end interlock A262 has a length and width that is the same or substantially the same as the length and width of the lower end of wall portion 200s-2 so as to cover the entire or substantially the entire lower end of wall portion 200s-2 as shown in FIG. 17.

The inner surface 226 of the seal plate 223 of the wall end interlock A262 is provided at its midpoint with an elongated key 222 which is rectangular in cross section and has a length equal to or substantially equal to the length of the wall end interlock A262. The key 222 is received in a corresponding elongated slot formed in the outer edge reinforcement located at the lower end of the wall section 200s-2 to which the wall end interlock A262 is fixed.

17, an elongated seal slot 240 is defined on the outer surface 227 of the wall end interlock A262 toward the inner end of the wall end interlock A262 (distal from the first transverse floor end 120). This seal slot 240 has a length equal to or substantially equal to the length of the wall end interlock A262. Additionally, each of the inner and outer ends of the wall end interlock A262 defines a locating slot 229. When the housing component 155 is wall portion 200s-2 in this case and utilizes the housing component stack design shown in FIG. 7, the locating slot 229 receives the ends of the sheet metal layers 205 and 216 folded at ninety degrees (90°) angles.

The wall end interlock A262 may be secured to the lower end of the wall section 200s-2, for example, by adhesive applied to its inner end surface 226, or by fasteners such as screws or nails spaced along the length of the wall end interlock A262 and driven through its outer surface 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 17, floor top interlock 261 mates with wall end interlock A 262. Prior to mating, shear seal 260 is placed in seal slot 240 of floor top interlock 261, and shear seal 260 is placed in seal slot 240 of wall end interlock A 262. The shear seals 260 placed in the seal slots 240 of floor top interlock 261 and wall end interlock A 262 each have the same or approximately the same length as the slot 240 into which they are inserted.

The engagement of the floor top interlock 261 with the wall end interlock A 262 occurs by the lower end of the wall portion 200s-2 moving over the upper surface of the floor portion 300b from a folded position to an unfolded position. Thus, in the arrangement shown in FIG. 17, such engagement corresponds to the wall portion 200s-2 moving from the right side of the figure to the left side, sliding over the floor top interlock A 261 until the wall end interlock A 262 reaches a fully unfolded position. In that fully unfolded position, the shear seal 260 of the floor top interlock 261, particularly its sealing surface 257, is in pressing contact with the outer surface 227 of the wall end interlock A 262, and the shear seal 260 of the wall end interlock A 262, particularly its sealing surface 257, is in sealing contact with the outer surface 227 of the floor top interlock 261. Consistent with this movement, the shear seal 260 disposed in the seal slot 240 of the floor top interlock 261 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 faces toward the outer end of the floor top interlock 261 (toward the first transverse floor end 120), and the shear seal 260 disposed in the seal slot 240 of the wall end interlock A 262 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 faces toward the inner end of the wall end interlock A 262 (away from the first transverse floor end 120).

To facilitate mating, the planar outer surface 227 of the floor top interlock 261 is preferably not parallel to the inner surface 226 of the floor top interlock 261 or the top surface of the wall portion 300b, but is preferably angled downwardly away from the first transverse floor edge 120 at an angle γ as shown in Figure 17. Similarly, the planar outer edge 227 of the wall end interlock A 262 is preferably angled upwardly at the same angle γ in a direction toward the first transverse floor edge 120 as shown in Figure 17. Thus, when the bottom edge of the wall portion 200s-2 moves over the top surface of the floor portion 300b from the folded position to the deployed position, the shear seals 260 located within the slots 240 of the floor top interlock 261 and the wall end interlock A 262 are compressed by the sliding movement of the wall end interlock A 262, providing two elongated seal areas between the floor portion 300b and the wall portion 200s-2. Also shown in Figure 17 for ease of mating is a step-down 268 on the outer surface 227 of the wall end interlock A 262. The step-down 268 is an abrupt decrease in thickness of the wall end interlock A 262 moving from the inner end of the wall end interlock A 262 toward the outer end of the wall end interlock A 262, which for the joint shown in Figure 17 is adjacent the first transverse floor end 120 when the wall section 200s-2 is in its fully deployed position. The step-down 268 is located between the slot 240 and the outer end of the wall end interlock A 262. Also shown in Figure 17 is a corresponding step-up 269 on the outer surface 227 of the floor top interlock 261. The step-up 269 is an abrupt increase in the thickness of the floor top interlock 261 in a direction moving from the inner end of the floor top interlock 261 toward the outer end of the floor top interlock 261, which, for the joint shown in FIG. 17, is adjacent to the first transverse floor end 120 when the floor section 300b is in a fully deployed position. The step-up 269 is located between the slot 240 and the inner end of the floor top interlock 261 (distal from the first transverse floor end 120). The step-down 268 and step-up 269 act as "stops" as the wall end interlock A 262 slides over the floor top interlock 261 and are appropriately positioned to ensure proper alignment of the wall end interlock A 262 with the floor top interlock 261.
J. Wall End Interlock B (263), Wall End Interlock A (262) Seal System

FIG. 18 shows an exploded view of the joint between wall end interlock B263 and wall end interlock A262, each shown in cross section. The particular joint is shown for illustrative purposes between wall portion 200s-2 and wall component 200P, with wall end interlock B263 located on the inner end of wall component 200P proximate first transverse end 108 and wall end interlock A262 located on the vertical end of wall portion 200s-2 proximate first longitudinal end 106. In structure 150, wall portion 200s-2 shown in FIG. 18 is vertical and wall component 200P is vertical.

In particular, the wall end interlock B263 of FIG. 18 is an elongated member having an elongated seal plate 223 having an elongated inner surface 226 and an opposing elongated planar outer surface 227. The outer surface 227 is preferably hard and smooth to provide a good sealing surface. The seal plate 223 has a length equal to or substantially equal to the height of the wall component 200P when deployed to cover the inner end of the wall component 200P proximate the first transverse end 108. The seal plate 223 of the wall end interlock B263 has a width equal to or substantially equal to the width of the wall portion 200s-2. In general terms, the design of the wall end interlock B263 is substantially the same as the floor top interlock 261 shown in FIG. 17, except that the wall end interlock B263 is thinner since it does not need to accommodate flooring. For example, the wall end interlock B263 can have a thickness "I" (not shown in FIG. 18) at its inner end equal to the thickness of the adjacent protective layer 218, such as an MgO board.

Referring again to FIG. 18, an elongated seal slot 240 is defined on the outer surface 227 of the wall end interlock B263 proximate the inner end of the wall component 200P adjacent the first longitudinal end 106. The seal slot 240 has a length the same as, or substantially the same as, the length of the wall end interlock B263.

The wall end interlock B263 may be secured to the inner end of the wall component 200P by adhesive applied to the inner surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the wall end interlock B263 and driven through the outer wall surface 227, or by utilizing a combination of adhesive and fasteners, as shown, for example, in FIG. 18.

18 further shows a wall end interlock A262 disposed along the illustrated vertical edge of the wall portion 200s-2. The design of the wall end interlock A262 was disclosed above in connection with FIG. 17. The seal plate 223 of the wall end interlock A262 shown in FIG. 18 has a length and width that is the same as or substantially the same as the length and width of the illustrated vertical edge of the wall portion 200s-2 so as to cover the entire or substantially the entire vertical edge of the wall portion 200s-2 as shown in FIG. 18. The elongated rectangular key 222 of the wall end interlock A262 shown in FIG. 18 has a length that is the same as or substantially the same as the length of the wall end interlock A262. The key 222 is received in a corresponding elongated slot formed in an outer edge reinforcement disposed at the vertical edge of the wall portion 200s-2 to which the wall end interlock A262 is fixed. The seal slot 240 of the wall end interlock A262 shown in FIG. 18 has a length that is the same as or substantially the same as the length of the wall end interlock A262. When the housing component 155, in this case wall portion 200s-2, utilizes the housing component stacking design shown in FIG. 7, the locating slots 229 of the wall end interlock A262 shown in FIG. 18 receive the ends of the sheet metal layers 205 and 216 that are folded at a ninety degree (90°) angle.

The wall end interlock A262 can be secured to the vertical end of the wall section 200s-2 shown in FIG. 18, for example, by adhesive applied to its inner end surface 226, or by fasteners such as screws or nail fasteners spaced along the length of the wall end interlock A262 and driven through its outer surface 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 18, wall end interlock A 262 mates with wall end interlock B 263. Prior to mating, a shear seal 260 is placed in the seal slot 240 of wall end interlock A 262 and a shear seal 260 is placed in the seal slot 240 of wall end interlock B 263. Each of the shear seals 260 placed in the seal slots 240 of wall end interlock A 262 and wall end interlock B 263 has the same or approximately the same length as the slot 240 into which it is inserted.

Engagement of wall end interlock A262 and wall end interlock B263 occurs by the vertical edge of wall portion 200s-2 shown in FIG. 18 swinging toward and across the inner surface of wall component 200P as wall portion 200s-2 moves from the folded position to the deployed position. Thus, in the arrangement shown in FIG. 18, such engagement corresponds to movement of wall portion 200s-2 from top to bottom of the figure, with wall end interlock A262 sliding across wall end interlock B263 until a fully deployed position is reached. In that fully deployed position, the shear seal 260 of wall end interlock A262, particularly its sealing surface 257, is in pressing contact with the outer surface 227 of wall end interlock B263, and the shear seal 260 of wall end interlock B263, particularly its sealing surface 257, is in sealing contact with the outer surface 227 of wall end interlock A262. Consistent with this movement, the shear seal 260 disposed in the seal slot 240 of the floor top interlock B 263 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 faces toward the outer end (toward the first transverse end 108) of the wall end interlock B 263, and the shear seal 260 disposed in the seal slot 240 of the wall end interlock A 262 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 faces toward the inner end (away from the first transverse end 108) of the wall end interlock A 262.

To facilitate mating, the planar outer edge 227 of wall end interlock B 263 is preferably not parallel to the inner edge 226 of wall end interlock B or the inner edge of the wall component 200P, but is inclined at an angle γ, as shown in Figure 17, so that the seal plate 223 of wall end interlock B 263 becomes gradually thinner away from the first transverse edge 108. Similarly, the planar outer edge 227 of wall end interlock A 262 is preferably inclined at the same angle, as shown in Figure 17, so that the seal plate 223 of wall end interlock A 262 becomes gradually thicker away from the first transverse edge 108. Thus, when the vertical end of the wall section 200s-2 swings transversely from the folded position to the deployed position toward the inner end of the wall component 200P, the shear seals 260 located in the slots 240 of the floor end interlocks A 262 and the wall end interlocks B 263 are compressed by the sliding movement of the wall end interlocks A 262 to provide two elongated seal areas between the wall component 200P and the wall section 200s-2. Also, to facilitate mating, a step-down 268 is provided on the outer surface 227 of the wall end interlocks A 262 as previously described. The step-down 268 provides an abrupt decrease in thickness of the wall end interlocks A 262 in a direction moving from the inner end of the wall end interlocks A 262 toward the outer end of the wall end interlocks A 262, which for the joint shown in FIG. 18 is adjacent the first transverse end 108 when the wall section 200s-2 is in the fully deployed position. The step down 268 is located between the slot 240 and the outer end of the wall end interlock A 262 (proximate the transverse end 108), as shown in Figure 18. Also shown in Figure 18 is a corresponding step up 269 on the outer surface 227 of the wall end interlock B 263. The step up 269 is an abrupt increase in thickness of the wall end interlock B 263 moving from the inner end of the wall end interlock B 263 towards the outer end of the wall end interlock B 263, which in the case of the joint shown in Figure 18 is proximate the first transverse end 108. The step up 269 is located between the slot 240 and the inner end of the wall end interlock B 263 (distal from the first transverse end 108). The step down 268 and step up 269 act as "stops" as wall end interlock A 262 slides across wall end interlock B 263 and are appropriately positioned to ensure proper alignment of wall end interlock A 262 with wall end interlock B 263.
K. Closure Board

Two of these inventive closure boards, the perimeter board 310 and the roof skirt board 280, are described below.
Perimeter Board (310)

Optionally, a perimeter board 310 is provided at the outer end or part of the floor component 300.

19A illustrates an exemplary positioning of the perimeter board 310 in cross section. In particular, the perimeter board 310 is designed to be positioned against an I-beam end cap 221, in this example, located at the outer end of the floor section 300a. The perimeter board 310 includes an elongated seal plate 223 and has an elongated inner surface 226 and an opposing outer surface 227. The perimeter board 310 has a desired length to span the entire outer end of the floor section 300a. As shown in FIG. 19A, the width of the perimeter board 310 can be sufficient to capture a portion of the adjacent wall component 200 or wall section in addition to the thickness of the floor component 300a, or the floor section on which it is located.

The elongated inner surface 226 of the perimeter board 310 includes an elongated positioning key 264 that is rectangular in cross section and sized to be received in the attachment slot 224 of the I-beam end cap 221. The positioning key 264 can be the same length as the perimeter board 310 or can be comprised of separate spaced apart segments. The elongated inner surface 226 of the perimeter board 310 of FIG. 19A also includes a plurality of clearance slots 266, which in the illustrated embodiment are rectangular in cross section and have a length the same as or substantially the same as the length of the perimeter board 310. The clearance slots 266 are preferably positioned such that when the positioning key 264 is received in the attachment slot 224, it is positioned over the positioning groove 225 of the I-beam end cap 221. When so positioned, the clearance slots 266 provide space for fastener heads driven into the positioning groove 225 of the I-beam end cap 221 to allow the perimeter board 310 to be positioned snugly against the I-beam end cap 221.

The outer surface 227 of the perimeter board 310 shown in FIG. 19A includes two elongated fastener slots 265, each of which in the illustrated embodiment is dovetail-shaped in cross section and has a length equal to or substantially equal to the length of the perimeter board 310. A locating groove 225 is provided in each fastener slot 265 to facilitate precise location of nails or other fasteners used to secure the perimeter board 310 to adjacent components.

Figure 19B shows in cross section the relative positions of the I-beam end cap 221, floor top plate 252, wall end cap 246, and perimeter board 310 at the joint between wall component 200R and floor section 300a. As shown, the perimeter board 310 not only conceals this joint from the outside to achieve a more attractive appearance, but also provides an additional barrier against the ingress of dirt, dust, rain, etc. A resilient strip 267 as shown in Figure 19B can be fitted into each of the fastener slots 265 to cover the heads of the nails or fasteners exposed in those slots.

Roof Skirtboard An optional roof skirtboard 280 is provided on the outer edge of the roof component 400, or a portion thereof.

20 illustrates an exemplary positioning of the roof skirtboard 280 in cross section. In particular, the roof skirtboard 280 is designed to be positioned against the I-beam end cap 221, which in this example is located at the outer end of the roof section 400a. The roof skirtboard 280 includes an elongated seal plate 223 and has an elongated inner surface 226 and an opposing outer surface 227. The roof skirtboard 280 has a desired length such that it spans the entire outer end of the roof section 400a. As shown in FIG. 20, the width of the roof skirtboard 280 can be sufficient to capture a portion of the adjacent wall component 200 or wall section in addition to the thickness of the roof component 400, or the portion thereof in which it is located.

The elongated inner surface 226 of the roof skirtboard 280 includes an elongated cinch key 278, which is preferably serpentine in cross section and sized to be received in the associated slot 224 of the I-beam end cap 221. The cinch key 278 may be the same length as the perimeter board 310 or may be comprised of spaced-apart individual segments. Meanwhile, the outer surface 227 of the roof skirtboard 280 includes an elongated fastener slot 265 disposed above the cinch key 278. The fastener slot 265 has a dovetail shape in cross section in the illustrated embodiment and is the same or substantially the same length as the length of the roof skirtboard 280. An elongated locating groove 225 is provided in the fastener slot 265 of the roof skirtboard 280 to visually indicate where to place the fastener during construction.

The roof skirt board 280 facilitates fastening of roofing material, such as a thermoplastic polyolefin membrane, to the wall component 200. Such roofing material is optionally used to cover the top of the roof component 400 after the roof section is fully deployed. The roofing material extending beyond the roof component 400 is then folded over to extend between the outer surface 227 of the I-beam end cap 221 of the roof section 400a shown in FIG. 20 and the inner surface 226 of the roof skirt board 280. After the roofing material is so positioned, nails or other fasteners are driven at intervals along the positioning grooves 225 to press the roof skirt board 280 against the roofing material and secure the roofing material in place between the roof skirt board 280 and the I-beam end cap 221. The fastening keys 278 provide additional surface area for better capture of the roofing material, if it is concertina-shaped in cross section or the like. An elongated resilient strip 267, as shown in FIG. 20, can be fitted into the fastener slot 265 to cover the head of the nail or fastener exposed in the slot.
Housing component seal construction materials

The housing component seal structures described herein can be made from many materials, such as wood, aluminum, plastic, etc. It is preferred to make the housing component seal structures from expanded polyvinyl chloride (PVC), particularly Celca expanded PVC. This material provides a tough, impact and crack resistant, lightweight material with a rigid, attractive exterior that further contributes to the structural rigidity of the housing component 155 in addition to contributing to the seal structure.
Example of housing component seal structure arrangement

21A and 21B of the exploded views of the structure 150 shown in FIG. 1 provide example arrangements of the housing component seal structures described herein. For illustrative purposes to better understand some of these example arrangements, some of the housing component seal structures shown in FIGS. 21A and 21B are shown slightly spaced apart from the housing component 155 to which they are secured.

With reference to FIG. 21A, I-beam end caps 221 can be utilized to seal the horizontal outer ends of floor section 300a (3 locations), floor section 300b (3 locations), roof section 300a (3 locations), roof section 300b (2 locations), and roof section 300c (3 locations). Additionally, as shown in FIG. 21B and shown in detail in FIG. 12, the hinged joint between wall sections 200s-1 and 200s-2 can be sealed by placing wall end caps 246 on the vertical ends of wall section 200s-1 and wall vertical interlocks 245 on the vertical ends of wall section 200s-2. Similarly, the hinged vertical joint between wall sections 200s-3 and 200s-4 can be sealed as shown in FIG. 21B by positioning a wall end cap 246 on the hinged vertical end of wall section 200s-3 and a wall vertical interlock 245 on the hinged vertical end of wall section 200s-4.

Furthermore, as shown in Figs. 21A and 21B and shown in detail in Fig. 13, the horizontal joint between the wall component 200R and the roof portion 400a can be sealed by positioning the roof bottom plate 255 on the bottom surface of the roof portion 400a covering the wall component 200R and positioning the wall end cap 246 on the horizontal end of the wall component 200R supporting the roof portion 400a. A similar sealing arrangement can be used to seal the horizontal joint between the roof portions 400a, 400b, 400c and the wall portions 200s-1 to 200s-4 (as can be seen in Fig. 3, the unfolded roof portion 400b rests on the unfolded wall portion 200s-2 and also rests on a part of the wall portion 200s-1) and also to seal the horizontal joint between the roof portion 400c and the wall component 200P. The two outer vertical ends of the wall component 200R can each be sealed by placing a wall end cap 246.

In a similar manner, as shown in detail in Figures 21A, 21B, and 15, the horizontal joint between the wall component 200R and the floor section 300a can be sealed by positioning a wall end cap 246 on the horizontal end of the wall component 200R resting on the floor section 300a and positioning a floor top plate 252 on the upper surface of the floor section 300a underlying the wall component 200R. A similar sealing arrangement can be used to seal the horizontal joints between the floor section 300b and the wall component 200P, and between the floor section 300a and the wall sections 200s-1 and 200s-3 up to the point where the wall section 200s-1 meets the wall section 200s-2, and up to the point where the wall section 200s-3 meets the wall section 200s-4. The two vertical outer ends of the wall component 200P can be sealed by placing a wall end cap 246 on each of them.

21A and in detail in FIG. 14, the hinged horizontal joint between roof portion 400b and roof portion 400c can be sealed by positioning I-beam interlock A250 on the inner end 412c of roof portion 400c and I-beam interlock B251 on the first inner end 412b of roof portion 400b. Similarly, the hinged horizontal joint between roof portion 400a and roof portion 400b shown in FIG. 21A can be sealed by positioning I-beam interlock A250 on the second inner end 412b of roof portion 400b and I-beam interlock B251 on the inner end 412a of roof portion 400a. Similarly, the hinged horizontal joint between floor section 300a and floor section 300b can be sealed by placing an I-beam interlock A 250 at inner end 301b of floor section 300b and an I-beam interlock B 251 at inner end 301a of floor section 300a.

21A, 21B, and in particular with reference to FIG. 17, the horizontal joint between wall portion 200s-2 and floor portions 300a, 300b may be sealed by placing a wall end interlock A 262 at the lower end of wall portion 200s-2 and a floor top interlock A 261 at the area of the upper surface of floor portions 300a, 300b underlying wall portion 200s-2 when wall portion 200s-2 is in its fully deployed position. The horizontal joint between wall portion 200s-4 and floor portions 300a and 300b when wall portion 200s-4 is in its fully deployed position may be similarly sealed.

21B and with particular reference to FIG. 18, the vertical joint between wall portion 200s-2 and wall component 200P may be sealed by positioning wall end interlock A 262 on the vertical end of wall portion 200s-2 adjacent wall component 200P when both are in their fully deployed positions, and by positioning wall end interlock B 263 on the area of the inner surface of wall component 200P adjacent wall portion 200s-2 when both are in their fully deployed positions. The vertical joint between wall portion 200s-4 and wall component 200P may be similarly sealed.

7, the metal sheets 206 and 217 that may be used to form the first structural layer 210 and the second structural layer 215, respectively, may be generally flat and juxtaposed in a simple adjacent relationship. Optionally, the metal sheets 206 and 217 may include edge structures that facilitate positioning of the sheets and panels during manufacture.

Specific end structure designs for metal sheets 206 and 217 are described in U.S. Non-Provisional Patent Application No. 17/504,883, entitled "Sheet/Panel Design for Enclosure Component Manufacture," filed October 19, 2021, and having the same inventors as the inventions described herein. The contents of U.S. Non-Provisional Patent Application No. 17/504,883, entitled "Sheet/Panel Design for Enclosure Component Manufacture," filed October 19, 2021, and having the same inventors as the inventions described herein, are incorporated by reference as if fully set forth herein, including in particular the outer end and inner end structure designs. See, for example, paragraphs 00187-00205 and 00212, and Figures 8, 9A-9C, 23A-23J, and 24A-24B thereof.

Equipment suitable for manufacturing the enclosure component 155, as well as exemplary manufacturing steps, are also described in U.S. Non-Provisional Patent Application No. 17/504,883, entitled "Sheet/Panel Design for Enclosure Component Manufacture," filed October 19, 2021, by the same inventor as the present application. The contents of U.S. Non-Provisional Patent Application No. 17/504,883, entitled "Sheet/Panel Design for Enclosure Component Manufacture," filed October 19, 2021, by the same inventor as the present application, are incorporated by reference as if fully set forth herein, in particular, for example, in paragraphs 00178-00186 and 00206-00222, and the exemplary manufacturing steps described in Figures 22, 23A-23J, and 24A-24B.

Assembly and Relationship of Housing Components for Shipping To facilitate ease of shipping and maximize design flexibility, it is preferred that there be specific dimensional relationships between the housing components 155.

2 is a top schematic view of the structure 150 shown in FIG. 1, including a geometric orthogonal grid for clarity in illustrating the preferred dimensional relationships between its housing components 155. The cardinal length used for sizing is shown in FIG. 2 as "E", and the orthogonal grid overlaid on FIG. 2 is 8E by 8E, and in particular, the entire structure 150, including the perimeter board 310, is preferably bounded by this 8E by 8E orthogonal grid.

Each of the roof sections 400a, 400b and 400c may have the same dimensions in the transverse direction. Alternatively, referring to FIG. 3, the roof section 400c (which is stacked on top of the roof sections 400a, 400b when the roof sections 400b, 400c are fully folded) may be dimensioned to be, for example, 10-15 percent larger in the transverse direction than either of the roof sections 400a and 400b, or at least the total thickness of the roof components 400a, 400b. This increased transverse dimension is to reduce the likelihood of folding or binding occurring during deployment of the roof sections 400b, 400c. Additionally, friction-reducing components may be used to facilitate deployment of the roof component 400, as disclosed in U.S. Non-Provisional Patent Application No. 16/786,315, entitled "Equipment and Methods for Erecting a Transportable Foldable Building Structure," filed February 10, 2020. For example, this can be facilitated by positioning a first wheel caster at a leading edge of roof portion 400c adjacent to a corner of roof portion 400c supported by wall portion 200s-2 when roof portion 400c is deployed, and by positioning a second similar wheel caster at a leading edge of roof portion 400c adjacent to a corner of roof portion 400c supported by wall portion 200s-4 when root portion 400c is deployed. In such a case, roof portion 400c can be dimensioned in a transverse direction larger than either roof portion 400a or 400b by at least the total thickness of roof components 400a and 400b minus the length of the first or second wheel caster.

In FIG. 2, each of the four wall components 200 is approximately 8E long, and each of the roof sections 400a and 400b is approximately 8E long and 2.5E wide. Roof section 400c is approximately 8E long and 2.9E wide. In FIGS. 2 and 3, each of the floor components 300a and 300b is 8H long, while floor component 300a is just over 3E wide and floor component 300b is just under 5E wide.

3 includes a fixed space portion 102 defined by a roof component 400a, a floor component 300a, a wall component 200R, a wall portion 200s-1, and a wall portion 200s-3. As shown in FIG. 2, a fourth wall portion 200s-4 is folded inwardly and positioned generally relative to the fixed space portion 102, and a second wall portion 200s-2 is folded inwardly and positioned generally relative to the fourth wall portion 200s-4 (wall portions 200s-2 and 200s-4, when so folded and positioned, are identified in FIG. 2 as portions 200s-2f and 200s-4f, respectively). The three roof components 400a, 400b and 400c are shown in an unfolded state in FIG. 1 and in a folded (stacked) state in FIG. 3, with the roof component 400b stacked on top of the roof component 400a and the roof component 400c stacked on top of the roof component 400b. The wall component 200P shown in FIG. 2 and FIG. 3 is rotatably fixed to the floor portion 300b at the position of the axis 105 and is arranged vertically to the outside of the wall portions 200s-2 and 200s-4. The floor portion 300b is then vertically arranged close to the fixed space portion 102 with the wall component 200P suspended from the floor portion 300b between the floor portion 300b and the wall portions 200s-2 and 200s-4.

Sizing the housing components 155 of the structure 150 according to the dimensional relationships disclosed above results in a compact shipping module 100, as can be seen in the figures. Thus, the shipping module 100 shown in FIG. 3 is sized according to the relationships disclosed herein using an "E" dimension (see FIG. 2) of approximately 28.625 inches (72.7 cm), and has an overall length of approximately 19 feet (5.79 m), an overall width of approximately 8.5 feet (2.59 m), and an overall height of approximately 12.7 feet (3.87 m) when its components are stacked and arranged as shown in FIG. 3. These overall dimensions are smaller than a typical shipping container.

The fixed space portion 102 is preferably in a relatively completed state before all other wall, roof and floor portions are positioned (folded) together as described above. In the embodiment shown in Figures 1 and 2, the wall component 200 is fitted with all necessary door and window assemblies during manufacture and prior to shipping, the enclosure component 155 is pre-wired, and the fixed space portion 102 is fitted with all mechanical and other features required by the structure 150, such as kitchens, bathrooms, closets and other interior partitions, storage areas, hallways, etc., during manufacture. The interior design of the fixed space portion 102 is described in U.S. Non-Provisional Application No. 17/587,051, entitled "Wall Component Appurtenances," filed on January 28, 2022 and by the same inventor as the present application. The contents of U.S. Non-Provisional Patent Application No. 17/587,051, entitled "Wall Component Appurtenances" by the present application and the inventor, filed on January 28, 2022, are incorporated by reference as if fully set forth herein, in particular the details of the internal design of the fixed space portion 102 described, for example, in paragraphs 0082-0085 and shown in Figures 11A-11C thereof. By carrying out the above steps prior to shipping, the builder can essentially erect a largely completed structure 150 by simply "deploying" the positioned components of the shipping module 100.

The wall, floor and roof components 200, 300, 400 and/or portions thereof may be covered with a protective film 177 during manufacture and prior to forming the shipping module 100. Alternatively or additionally, the entire shipping module 100 may be covered with a protective film. Such a protective film may remain in place until after the shipping module 100 arrives at the construction site and then be removed as needed to facilitate unfolding and finishing of the enclosure components.
Shipping Module

The shipping module 100 is transported to the construction site by suitable transportation. One such transportation is disclosed in U.S. Pat. No. 11,007,921, issued May 18, 2021, the contents of which, particularly those shown in paragraphs 0020-0035 and Figures 1A-2D, are incorporated by reference as if fully set forth herein. As an alternative transportation, the shipping module 100 can be shipped to the construction site by conventional truck trailers or low-bed trailers (also called lowboy trailers), and by ship for water transport.

Movement of the shipping module 100 is facilitated by the presence of the fork tubes 360a, 360b in the floor section 300a. For example, the shipping module can be moved from the factory to the transport using an appropriately sized forklift with the forks of the forklift inserted into the fork tubes 360a, 360b. As another example, straps reserved from a reach stacker or ship-to-shore crane typically used to move intermodal containers can be threaded through the fork tubes 360a, 360b by ground personnel and then appropriately secured to allow movement of the shipping module 100. The addition of the perimeter board 310 can be postponed until the shipping module 100 is delivered to the desired location. Alternatively, the perimeter board 310 can include cutouts to allow straps or forks to access the fork tubes 360a, 360b, which can be optionally covered and/or filled in once access to the fork tubes 360a, 360b is no longer required.
Development and finishing of the structure

At the building site, the shipping module 100 is positioned on the desired location, such as on a prepared foundation, such as a poured concrete slab, a poured concrete or cinder block foundation, a sleeper beam or concrete column or pillar, etc. This can be accomplished by using a crane to lift the shipping module 100 from the transport vehicle and move it to the desired location, or by positioning the transport vehicle over the desired location, lifting the shipping module 100, then moving the transport vehicle from the desired location, and then lowering the shipping module 100 to rest at the desired location. Particularly suitable apparatus and techniques for facilitating positioning of the shipping module 100 at the desired location are disclosed in U.S. Nonprovisional Patent Application No. 16/786,315, filed February 10, 2020, entitled "Equipment and Methods for Erecting a Transportable Foldable Building Structure." 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," filed Feb. 10, 2020) are incorporated by reference as if fully set forth herein, including, in particular, the apparatus and techniques described, for example, in paragraphs 00126-00128 and in connection with Figures 11A and 11B thereof.

Following positioning of the shipping module 100 at the construction site, the appropriate portions of the wall, floor and roof components 200, 300 and 400 are "unfolded" (i.e., deployed) to obtain the structure 150. The unfolding operation is performed in the following order: (1) the floor portion 300b is pivotally rotated about horizontal axis 305 (shown in FIGS. 3 and 4) to the unfolded position; (2) the wall component 200P is pivotally rotated about horizontal axis 105 (shown in FIG. 3 behind the perimeter board 312) to the unfolded position; (3) the wall portions 200s-2 and 200s-4 are pivotally rotated about vertical axes 192 and 194 (shown in FIG. 2), respectively, to the unfolded position; and (4) the roof portions 400b and 400c are pivotally rotated about horizontal axes 405a and 405b (shown in FIGS. 3 and 4), respectively, to the unfolded position.

A mobile crane can be used to assist in the unfolding of portions of the enclosure component 155, specifically the roof portions 400b and 400c, the floor portion 300b, and the wall component 200P pivotally secured to the floor portion 300b. Alternatively, particularly suitable devices and techniques for facilitating the unfolding of the enclosure component 155 are disclosed in U.S. Non-Provisional Patent Application No. 16/786,315, entitled "Equipment and Methods for Erecting a Transportable Foldable Building Structure," filed February 10, 2020. The contents of U.S. Non-Provisional Patent Application No. 16/786,315 (entitled "Equipment and Methods for Erecting a Transportable Foldable Building Structure," filed February 10, 2020), are incorporated by reference herein as if fully set forth herein, in particular the devices and techniques described, for example, in paragraphs 0132-00145 and illustrated in Figures 12A-14B thereof.

After deployment, the enclosure components 155 are secured together to complete the structure 150 shown in FIG. 1. The perimeter boards 312 and roof skirting boards 280 provide structure for securing the wall, floor and roof components in the deployed position. Additionally, certain accessories may be attached to the wall components 200 to facilitate fastening the wall components 200 to the floor components 300, as well as to enhance the interior appearance and expedite fabrication. Further details regarding these accessories are described in U.S. Non-Provisional Patent Application No. 17/587,051, entitled "Wall Component Appurtenances," filed January 28, 2022, and by the same inventor as the present disclosure. The contents of U.S. Non-Provisional Patent Application No. 17/587,051, entitled "Wall Component Appurtenances," filed on January 28, 2022, by the same inventor as the present disclosure, are incorporated by reference as if fully set forth herein, particularly including, for example, the first and second accessory designs described in paragraphs 0047-0061 and shown in Figures 8A-10C thereof.

If temporary hinge structures were utilized, these can be removed if desired and the housing components 155 can be secured together. During or after the housing components 155 are unfolded and secured, any remaining finishing work as pertinent herein can be performed, such as adding roofing material and hooking up electrical, fresh water, and sewer lines to complete the structure 150.
Building Configuration Options

Any number of structures 150 can be arranged together in any desired location to provide a number of different structural configurations. Internal stairs for such multi-level structures can be provided during manufacture of the fixed space portion 102 with appropriate access openings inserted in the roof component 400, or can be added after erection. Similarly, pitched roofs and other architectural additions can be delivered separately from the shipping module 100 or fabricated on-site and placed on the roof component 400 of the structure 150.

For example, two or more structures 150 can be erected such that the wall components 200 of one structure are adjacent to the wall components 200 of the other structure. The builder can then cut openings in the juxtaposed areas to connect the two structures, either in the factory or on-site, as selected by the seller or purchaser. As an example, FIG. 22 shows a floor plan of three structures 150, namely 150a, 150b and 150c, arranged side-by-side to achieve one housing unit having three rooms. In such a case, the perimeter boards 310 of adjacent structures 150 can be adjacent to each other, thereby providing space between the adjacent structures 150 through which utility lines can be passed.

The structures 150 can also be stacked one on top of the other to create a multi-storey structure. Figure 23 shows structure 150e being placed on top of structure 150d to create a two-storey structure. Thus, as shown in Figure 23, the first floor has a garage opening 203 in addition to the door opening 202, and the second floor has a door opening 202 (not shown) accessible via an external staircase 201.

When stacking structures 150, such as stacking structure 150e shown in FIG. 23 on structure 150d, spacer plates 404 can be used to separate the floor component 300 of structure 150e from the roof component 400 of structure 150d. FIG. 24 shows one embodiment of a spacer plate 404, which comprises a planar base 402 having an inner surface 407, an opposing outer surface 401 (not shown in FIG. 24), and a thickness. A lip 403 extends perpendicularly from the inner surface 407 of the base 402. An end 421 of the lip 403 distal from the inner surface 407 is provided with a set of stepped locating ridges 253. These ridges 253 are shaped to be able to mate with corresponding stepped locating ridges 253 shown on the I-beam end caps 221.

In use, the spacer plates 404 can be provided on the bottom surface of the floor component 300 of the upper structure 150 (structure 150e in FIG. 23) positioned along the first and second longitudinal floor edges 117 and 119 and along the first and second transverse floor edges 120 and 118. Spacer plates 404 can also be provided on the top surface of the roof component 400 of the lower structure 150 (structure 150d in FIG. 23) positioned along the first and second longitudinal roof edges 406 and 416 and along the first and second transverse roof edges 408 and 410.

The spacer plates 404 associated with the upper structure 150 can be positioned to cover the spacer plates 404 associated with the lower structure 150. When the spacer plates 404 are employed in this manner, the spacer plates 404 associated with the upper structure 150 support the weight and load of the upper structure 150 and transfer the weight and load to the lower structure 150 via the spacer plates 404 associated with the lower structure 150. As shown in FIG. 25, the locating ridges 253 on the spacer plates 404 engage corresponding locating ridges 253 on the I-beam end caps 221 of the floor component 300 (shown for floor portion 300a) and the roof component 400 (shown for roof portion 400a).

24 as having a relatively square shape, the spacer plates 404 can be elongated or preferably have a length equal to or substantially equal to the length of the edge of the roof or floor on which they are placed. If the length of the spacer plates 404 is less than the length of the edge of the roof or floor on which they are placed, multiple spacer plates can be provided, again split along their edges, as desired. Such spacer plates 404 provide an air barrier between levels of a multi-storey structure. The spacer plates 404 can be made, for example, from acrylonitrile butadiene styrene plastic or extruded polyvinyl chloride plastic.

If desired, means for fastening the stacked structures 150 to each other may be utilized, for example, steel reinforcing plates secured at spaced locations may be used to join the overlying floor component 300 to the underlying roof component 400.

The present disclosure should be understood to include, by way of example and not limitation, the subject matter set forth in the following numbered aspects:
Aspect 1
1. A spacer system for stacked housing components, comprising:
(a) a first housing component having a horizontal first side, an opposing horizontal second side, and an end having an end length;
(b) an elongated, planar first seal plate having a first seal plate end, an opposing second seal plate end, a seal plate outer surface, an opposing seal plate inner surface, and a seal plate thickness, the first seal plate end having a first set of stepped locating ridges extending inwardly of the seal plate thickness from the first seal plate end toward the second seal plate end, the seal plate inner surface being secured to the end of the first housing component;
(b) a spacer plate including a planar base with a spacer plate outer surface, an opposing spacer plate inner surface, a spacer plate thickness, and a lip extending away from the spacer plate inner surface, the lip having an end distal from the spacer plate inner surface having a second set of stepped locating ridges;
c) a spacer system, wherein the spacer plate inner surface is positioned against a horizontal first surface of a first housing component adjacent the end of the first housing component, and the second set stepped positioning ridges are in a mating relationship with the first set stepped positioning ridges.
Aspect 2
A spaced apart stacked architectural structure,
(a) a first architectural structure, the first architectural structure comprising:
(i) a floor component having a bottom surface, an opposing top surface, and an end portion having a floor end length;
(ii) an elongated, planar first seal plate having a first seal plate end, an opposing second seal plate end, a seal plate outer surface, an opposing seal plate inner surface, and a seal plate thickness, the first seal plate end having a first set of stepped locating ridges extending inwardly through the seal plate thickness from the first seal plate end toward the second seal plate end, the seal plate inner surface of the first seal plate being secured to the end of the floor component;
(iii) a first spacer plate including a planar base with a first spacer plate outer surface, an opposing first spacer plate inner surface, a thickness, and a lip extending away from the first spacer plate inner surface, the lip having an end distal from the first spacer plate inner surface having a second set of stepped locating ridges;
(iv) the first spacer plate inner surface is positioned against the bottom surface of the floor component adjacent the end of the floor component, the second set stepped locating ridges being in mating relationship with the first set "stepped" locating ridges;
(b) a second architectural structure, the second architectural structure comprising:
(i) a roof component having a bottom surface, an opposing top surface, and an end portion having a roof end length;
(ii) an elongated, planar second seal plate having a first seal plate end, an opposing second seal plate end, a seal plate outer surface, an opposing seal plate inner surface, and a seal plate thickness;
the first seal plate end of the second seal plate has a third set of stepped locating ridges extending from the first seal plate end of the second seal plate toward the second seal plate end thereof and inwardly into the seal plate thickness of the second seal plate, the seal plate inner surface of the second seal plate being secured to the end of the roof component;
(iii) a second spacer plate including a planar base with a second spacer plate outer surface, an opposing second spacer plate inner surface, a thickness, and a lip extending away from the second spacer plate inner surface, the lip having an end distal from the second spacer plate inner surface having a fourth set of stepped locating ridges;
(iv) the second spacer plate inner surface is positioned against the top surface of the roof component adjacent the end of the roof component, the fourth set stepped locating ridges being in mating relationship with the third set stepped locating ridges;
(c) the first spacer plate outer surface is positioned against the second spacer plate outer surface.
Aspect 3
2. The spacer system of claim 1, wherein the spacer plate has a spacer plate length that is the same as the end length.
Aspect 4
2. The spacer system of claim 1, wherein the spacer plate is one of a plurality of spacer plates secured to the horizontal first surface of the first housing component adjacent the end of the first housing component.
Aspect 5
5. The spacer system of claim 1, 3 or 4, further comprising a third set of stepped locating ridges extending inwardly through the seal plate thickness from the second seal plate end to the first seal plate end.
Aspect 6
6. The spacer system of claim 1, 3, 4 or 5, wherein the seal plate is made of polyvinyl chloride.
Aspect 7
A spacer system according to any one of the preceding aspects, wherein the spacer plates are made of either acrylonitrile butadiene styrene or polyvinyl chloride.
Aspect 8
The first housing component is a planar laminate, and the planar laminate comprises:
(i) a planar foam panel layer having a first surface and an opposing second surface;
(ii) a first planar structural layer having an inner surface bonded to the first surface of the foam panel layer and an outer surface;
(iii) a second planar structural layer adhered to the second surface of the foam panel layer.
Aspect 9
9. The spacer system of claim 8, wherein the first structural layer is a metal sheet layer.
Aspect 10
A spacer system as described in any one of claims 8 to 9, wherein the outer surface of the first structural layer coincides with the first surface of the first housing component.
Aspect 11
11. The spacer system of any one of aspects 8, 9, or 10, wherein the second structural layer is a metal sheet layer.
Aspect 12
3. The stacked architectural structure of claim 2, wherein the first spacer plate has a spacer plate length equal to the length of the floor edge.
Aspect 13
13. The stacked architectural structure of claim 12, wherein the second spacer plate has a spacer plate length equal to the roof edge length.
Aspect 14
3. The stacked architectural structure of claim 2, wherein the first spacer plate is one of a first plurality of spacer plates positioned against the bottom surface of the floor component adjacent the end of the floor component.
Aspect 15
15. The stacked architectural structure of any one of aspects 2, 12 or 14, wherein the second spacer plate is one of a second plurality of spacer plates positioned against the bottom surface of the floor component adjacent the end of the floor component.
Aspect 16
16. The stacked architectural structure of any one of aspects 2, 12-15, further comprising a fifth set of stepped positioning ridges extending inwardly through the seal plate thickness from the second seal plate end of the first seal plate to the first seal plate end of the first seal plate.
Aspect 17
17. The stacked architectural structure of any one of aspects 2, 12-16, further comprising a sixth set of stepped positioning ridges extending inwardly through the seal plate thickness from the second seal plate end of the second seal plate to the first seal plate end of the second seal plate.
Aspect 18
18. The laminated architectural structure of any one of claims 2, 12-17, wherein each of the first seal plate and the second seal plate is made of polyvinyl chloride.
Aspect 19
19. The laminated architectural structure of any one of aspects 2, 12-18, wherein each of the first spacer plate and the second spacer plate is made of either acrylonitrile butadiene styrene or polyvinyl chloride.
Aspect 20
The floor component is a planar laminate, the planar laminate comprising:
(i) a planar foam panel layer having a first surface and an opposing second surface;
(ii) a first planar structural layer having an inner surface bonded to the first surface of the foam panel layer and an outer surface;
(iii) a planar second structural layer having a first surface bonded to the second surface of the foam panel layer and an opposing second surface.
Aspect 21
21. The laminated architectural structure of claim 20, wherein the first structural layer of the floor component is a metal sheet layer.
Aspect 22
22. The laminated architectural structure of claim 20 or 21, wherein the outer surface of the first structural layer of the floor component coincides with the bottom surface of the floor component.
Aspect 23
23. The laminated architectural structure of claim 20, 21 or 22, wherein the second structural layer of the floor component is a metal sheet layer.
Aspect 24
24. The laminated architectural structure of claim 20, 21, 22 or 23, wherein the floor component further comprises a protective layer having a first side and an opposing second side, the first side of the protective layer being adhered to the opposing second side of the second structural layer.
Aspect 25
The roof component is a planar laminate, the planar laminate comprising:
(i) a planar foam panel layer having a first surface and an opposing second surface;
(ii) a first planar structural layer having an inner surface bonded to the first surface of the foam panel layer and an outer surface;
(iii) a planar second structural layer having a first surface adhered to the second surface of the foam panel layer and an opposing second surface.
Aspect 26
26. The laminated architectural structure of claim 25, wherein the first structural layer of the roof component is a metal sheet layer.
Aspect 27
27. The laminated architectural structure of claim 25 or 26, wherein the exterior surface of the first structural layer of the roof component coincides with the top surface of the roof component.
Aspect 28
28. The laminated architectural structure of claim 25, 26 or 27, wherein the second structural layer of the roof component is a metal sheet layer.
Aspect 29
30. The laminated architectural structure of claim 25, 26, 27 or 28, wherein the roof component further comprises a protective layer having a first side and an opposing second side, the first side of the protective layer being adhered to the opposing second side of the second structural layer.
Aspect 30
25. The laminated architectural structure of claim 24, wherein the protective layer is made of MgO.
Aspect 31
30. The laminated architectural structure of claim 29, wherein the protective layer is made of MgO.
Aspect 32
A folded building structure that can be transported to a location where construction is desired,
(a) a fixed space portion including a planar, rectangular first floor portion having first and second longitudinal floor ends, first and second transverse floor ends, and a thickness, the first floor portion having a thickness along the direction of:
(i) a first structural layer having a first surface and an opposing second surface;
(ii) a foam panel layer having a first surface and an opposing second surface, the first surface of the foam panel layer being adhered to the opposing second surface of the first structural layer;
(iii) a second structural layer having a first surface and an opposing second surface, the first surface of the second structural layer being adhered to the opposing second surface of the foam panel layer;
(iv) a first end reinforcement adjacent the first longitudinal floor end and a second end reinforcement adjacent the second longitudinal floor end;
(b) the first floor portion is between the first structural layer and the second structural layer,
(i) a first fork tube oriented in a transverse direction and spanning a distance from the first longitudinal floor end to the second longitudinal floor end to define a first opening at the first longitudinal floor end and a second opening at the second longitudinal floor end;
(ii) a planar, elongated, longitudinally oriented first fork tube plate secured to the first end reinforcement and to the first fork tube;
(iv) a planar, elongated, longitudinally oriented second fork pipe plate secured to the second end reinforcement and to the first fork pipe,
Aspect 33
(b) the first floor portion further comprises, between the first structural layer and the second structural layer,
(ii) a second fork tube oriented in a transverse direction and spaced from the first fork tube to span the distance from the first longitudinal floor end to the second longitudinal floor end so as to define a third opening at the first longitudinal floor end and a fourth opening at the second longitudinal floor end; and
(ii) a planar, elongated, longitudinally oriented third fork tube plate secured to the first end reinforcement and to the second fork tube; and
(iv) a planar, elongated, longitudinally oriented fourth fork tube plate secured to the second end reinforcement and to the first fork tube.
Aspect 34
34. The folded architectural structure of claim 33, wherein the first fork pipe plate extends beyond the first fork pipe in a direction away from the second fork pipe along the first end reinforcement, and the third fork pipe plate extends beyond the second fork pipe in a direction opposite to the direction away from the first fork pipe along the first end reinforcement.
Aspect 35
34. The folded architectural structure of claim 33, wherein the second fork pipe plate extends beyond the first fork pipe in a direction away from the second fork pipe along the second end reinforcement, and the fourth fork pipe plate extends beyond the second fork pipe in a direction opposite to the direction away from the first fork pipe along the second end reinforcement.
Aspect 36
36. The folded architectural structure of aspect 32, 33, 34 or 35, wherein the first structural layer of the floor portion is a metal sheet layer.
Aspect 37
37. The folded architectural structure of claim 33, 34, 35 or 36, wherein the first and second fork pipes are rectangular in cross section.
Aspect 38
38. The folded architectural structure of aspect 33, 34, 35, 36 or 37, wherein the first and second fork tubes are in contact with the first structural layer.
Aspect 39
(d) a planar, rectangular second floor portion having third and fourth longitudinal floor ends, third and fourth transverse floor ends, and a thickness, the second floor portion having a laminated construction across the thickness;
(i) a first structural layer having a first surface and an opposing second surface;
(ii) a foam panel layer having a first surface and an opposing second surface, the first surface of the foam panel layer being adhered to the opposing second surface of the first structural layer;
(iii) a second structural layer having a first surface and an opposing second surface, the first surface of the second structural layer being adhered to the opposing second surface of the foam panel layer;
(f) The folded architectural structure according to any of aspects 32 to 38, wherein the second floor section has means for pivotally connecting the floor section to the second floor section such that the second floor section can rotate angularly about a horizontal axis proximate the second and third longitudinal floor ends, the angular rotation being from a folded position of the second floor section oriented at an angle to the first floor section to an unfolded position of the second floor section coplanar with the first floor section.
Aspect 40
A folded building structure that can be transported to a location where construction is desired,
(a) a fixed space portion including a planar, rectangular first floor portion having first and second longitudinal floor ends, first and second transverse floor ends, and a thickness, the first floor portion having a laminated structure, the laminated structure having a thickness direction of:
(i) a first structural layer having a first surface and an opposing second surface;
(ii) a foam panel layer having a first surface and an opposing second surface, the first surface of the foam panel layer being adhered to the opposing second surface of the first structural layer;
(iii) a second structural layer having a first surface and an opposing second surface, the first surface of the second structural layer being adhered to the opposing second surface of the foam panel layer;
(iv) a first end reinforcement adjacent the first longitudinal floor end and a second end reinforcement adjacent the second longitudinal floor end;
(b) a first beam reinforcing the laminated structure and oriented transversely, the first beam having a first end disposed adjacent the first longitudinal floor edge and a second end disposed adjacent the second longitudinal floor edge;
(c) the first floor portion is between the first structural layer and the second structural layer,
(i) a first fork tube oriented in the transverse direction and spaced from a first side of the first beam, the first fork tube spanning a distance from the first longitudinal floor end to the second longitudinal floor end such that the first fork tube defines a first opening at the first longitudinal floor end and a second opening at the second longitudinal floor end;
(ii) a planar, elongated, longitudinally oriented first fork tube plate disposed relative to the first end reinforcement and secured to the first end reinforcement and the first fork tube, the first fork tube plate having a longitudinal length spanning a distance between the first fork tube and the first beam; and
(iv) a folded architectural structure comprising a planar, elongated, longitudinally oriented second fork tube plate positioned against the second end reinforcement and secured to the second end reinforcement and to the first fork tube, the second fork tube plate having a longitudinal length spanning the distance between the first fork tube and the first beam.
Aspect 41
(b) the first floor portion further comprises, between the first structural layer and the second structural layer,
(ii) a second fork tube oriented transversely and spaced from a second side of the first beam opposite the first side, the second fork tube spanning the distance from the first longitudinal floor end to the second longitudinal floor end to define a third opening at the first longitudinal floor end and a fourth opening at the second longitudinal floor end;
(ii) a planar, elongated, longitudinally oriented third fork tube plate secured to the first end reinforcement and the second fork tube, the third fork tube plate having a longitudinal length spanning a distance between the second fork tube and the first beam; and
(iv) a planar, elongated, longitudinally oriented fourth fork tube plate secured to the second end reinforcement and the first fork tube, the fourth fork tube plate having a longitudinal length spanning the distance between the second fork tube and the first beam.
Aspect 42
42. The folded architectural structure of claim 41, wherein the first fork pipe plate extends beyond the first fork pipe in a direction away from the first beam along the first end reinforcement, and the third fork pipe plate extends beyond the second fork pipe in a direction opposite to the direction away from the first beam along the first end reinforcement.
Aspect 43
43. The folded architectural structure of claim 41 or 42, wherein the second fork pipe plate extends beyond the first fork pipe in a direction away from the first beam along the second end reinforcement, and the fourth fork pipe plate extends beyond the second fork pipe in a direction opposite to the direction away from the first beam along the second end reinforcement.
Aspect 44
44. The folded architectural structure according to aspect 40, 41, 42 or 43, wherein the first structural layer of the floor portion is a metal sheet layer.
Aspect 45
45. The folded architectural structure of claim 41, 42, 43 or 44, wherein the first and second fork pipes are rectangular in cross section.
Aspect 46
46. The folded architectural structure of claim 45, wherein the first and second fork pipes are in contact with the first structural layer.
Aspect 47
(d) a planar, rectangular second floor portion having third and fourth longitudinal floor ends, third and fourth transverse floor ends, and a thickness, the second floor portion having a laminated construction across the thickness;
(i) a first structural layer having a first surface and an opposing second surface;
(ii) a foam panel layer having a first surface and an opposing second surface, the first surface of the foam panel layer being adhered to the opposing second surface of the first structural layer;
(iii) a second structural layer having a first surface and an opposing second surface, the first surface of the second structural layer being adhered to the opposing second surface of the foam panel layer;
(e) a second beam reinforcing the laminated structure of the second floor section and oriented transversely, the second beam having a third end disposed adjacent the third longitudinal floor end and a fourth end disposed adjacent the fourth longitudinal floor end;
(f) The folded architectural structure of aspect 40, 41, 42, 43, 44 or 45, wherein the third end of the second beam is pivotally connected to the second end of the first beam such that the second floor section can be angularly rotated about a horizontal axis proximate the second and third longitudinal floor ends, the angular rotation being from a second floor section folded position oriented at an angle to the first floor section to an unfolded position of the second floor section coplanar with the first floor section.
Aspect 48
Aspects 33-35, 37-38, and 41-47, wherein the second fork pipe is a metal sheet layer.
Aspect 49
Aspects 33-35, 37-38, and 41-48. The folded architectural structure of any one of aspects 33-35, 37-38, and 41-48, wherein each of the third and fourth fork tube plates is made of metal.
Aspect 50
Aspects 32-49. The folded architectural structure of any one of aspects 32-49, wherein the first fork pipe is made of metal.
Aspect 51
Aspects 32-50. The folded architectural structure of any one of aspects 32-50, wherein each of the first and second fork tube plates is made of metal.
Aspect 52
52. The folded architectural structure of claim 48, 49, 50 or 51, wherein the metal is steel.
Aspect 53
Aspect 53. The folded architectural structure of any of aspects 32-52, wherein each of the first and second end reinforcements is laminated strand lumberboard.

Claims (53)

1. A spacer system for stacked housing components, comprising:
(a) a first housing component having a horizontal first side, an opposing horizontal second side, and an end having an end length;
(b) an elongated, planar first seal plate having a first seal plate end, an opposing second seal plate end, a seal plate outer surface, an opposing seal plate inner surface, and a seal plate thickness, the first seal plate end having a first set of stepped locating ridges extending inwardly of the seal plate thickness from the first seal plate end toward the second seal plate end, the seal plate inner surface being secured to the end of the first housing component;
(b) a spacer plate including a planar base with a spacer plate outer surface, an opposing spacer plate inner surface, a spacer plate thickness, and a lip extending away from the spacer plate inner surface, the lip having an end distal from the spacer plate inner surface having a second set of stepped locating ridges;
(c) a spacer system, wherein the spacer plate inner surface is positioned against the horizontal first surface of the first housing component adjacent the end of the first housing component, and the second set stepped positioning ridges are in a mating relationship with the first set stepped positioning ridges. A spaced apart stacked architectural structure,
(a) a first architectural structure, the first architectural structure comprising:
(i) a floor component having a bottom surface, an opposing top surface, and an end portion having a floor end length;
(ii) an elongated, planar first seal plate having a first seal plate end, an opposing second seal plate end, a seal plate outer surface, an opposing seal plate inner surface, and a seal plate thickness, the first seal plate end having a first set of stepped locating ridges extending inwardly through the seal plate thickness from the first seal plate end toward the second seal plate end, the seal plate inner surface of the first seal plate being secured to the end of the floor component;
(iii) a first spacer plate including a planar base with a first spacer plate outer surface, an opposing first spacer plate inner surface, a thickness, and a lip extending away from the first spacer plate inner surface, the lip having an end distal from the first spacer plate inner surface having a second set of stepped locating ridges;
(iv) the first spacer plate inner surface is positioned against the bottom surface of the floor component adjacent the end of the floor component, the second set stepped locating ridges being in mating relationship with the first set stepped locating ridges;
(b) a second architectural structure, the second architectural structure comprising:
(i) a roof component having a bottom surface, an opposing top surface, and an end portion having a roof end length;
(ii) an elongated, planar second seal plate having a first seal plate end, an opposing second seal plate end, a seal plate outer surface, an opposing seal plate inner surface, and a seal plate thickness, the first seal plate end of the second seal plate having a third set of stepped locating ridges extending from the first seal plate end of the second seal plate toward the second seal plate end thereof and inwardly of the seal plate thickness of the second seal plate, the seal plate inner surface of the second seal plate being secured to the end of the roof component;
(iii) a second spacer plate including a planar base with a second spacer plate outer surface, an opposing second spacer plate inner surface, a thickness, and a lip extending away from the second spacer plate inner surface, the lip having an end distal from the second spacer plate inner surface having a fourth set of stepped locating ridges;
(iv) the second spacer plate inner surface is positioned against the top surface of the roof component adjacent the end of the roof component, the fourth set stepped locating ridges being in mating relationship with the third set stepped locating ridges;
(c) the first spacer plate outer surface is positioned against the second spacer plate outer surface. The spacer system of claim 1, wherein the spacer plate has a spacer plate length equal to the end length. The spacer system of claim 1, wherein the spacer plate is one of a plurality of spacer plates fixed to the horizontal first surface of the first housing component adjacent the end of the first housing component. The spacer system of claim 1, further comprising a third set of stepped locating ridges extending inwardly through the seal plate thickness from the second seal plate end to the first seal plate end. The spacer system of claim 1, wherein the seal plate is made of polyvinyl chloride. The spacer system of claim 1, wherein the spacer plate is made of either acrylonitrile butadiene styrene or polyvinyl chloride. The first housing component is a planar laminate, and the planar laminate comprises:
(i) a planar foam panel layer having a first surface and an opposing second surface;
(ii) a first planar structural layer having an inner surface bonded to the first surface of the foam panel layer and an outer surface;
10. The spacer system of claim 1 including: (iii) a second planar structural layer adhered to said second surface of said foam panel layer. The spacer system of claim 8, wherein the first structural layer is a metal sheet layer. The spacer system of claim 9, wherein the outer surface of the first structural layer coincides with the first surface of the first housing component. The spacer system of claim 10, wherein the second structural layer is a metal sheet layer. The stacked architectural structure of claim 2, wherein the first spacer plate has a spacer plate length equal to the length of the floor edge. The stacked architectural structure of claim 12, wherein the second spacer plate has a spacer plate length equal to the roof edge length. The stacked architectural structure of claim 2, wherein the first spacer plate is one of a first plurality of spacer plates positioned against the bottom surface of the floor component adjacent the end of the floor component. The stacked architectural structure of claim 2, wherein the second spacer plate is one of a second plurality of spacer plates positioned against the bottom surface of the floor component adjacent the end of the floor component. The stacked architectural structure of claim 2, further comprising a fifth set of stepped locating ridges extending inwardly through the seal plate thickness from the second seal plate end of the first seal plate to the first seal plate end of the first seal plate. The stacked architectural structure of claim 2, further comprising a sixth set of stepped locating ridges extending inwardly through the seal plate thickness from the second seal plate end of the second seal plate to the first seal plate end of the second seal plate. The laminated architectural structure of claim 2, wherein each of the first seal plate and the second seal plate is made of polyvinyl chloride. The laminated architectural structure of claim 2, wherein each of the first spacer plate and the second spacer plate is made of either acrylonitrile butadiene styrene or polyvinyl chloride. The floor component is a planar laminate, the planar laminate comprising:
(i) a planar foam panel layer having a first surface and an opposing second surface;
(ii) a first planar structural layer having an inner surface bonded to the first surface of the foam panel layer and an outer surface;
3. The laminated architectural structure of claim 2, further comprising: (iii) a planar second structural layer having a first surface adhered to the second surface of the foam panel layer and an opposing second surface. The laminated architectural structure of claim 20, wherein the first structural layer of the floor component is a metal sheet layer. 22. The laminated architectural structure of claim 21, wherein the outer surface of the first structural layer of the floor component coincides with the bottom surface of the floor component. The laminated architectural structure of claim 20, wherein the second structural layer of the floor component is a metal sheet layer. 24. The laminated architectural structure of claim 23, wherein the floor component further comprises a protective layer having a first surface and an opposing second surface, the first surface of the protective layer being adhered to the opposing second surface of the second structural layer. The laminated architectural structure of claim 2, wherein the roof component is a planar laminate having: (i) a planar foam panel layer having a first surface and an opposing second surface; (ii) a planar first structural layer having an inner surface and an outer surface bonded to the first surface of the foam panel layer; and (iii) a planar second structural layer having a first surface and an opposing second surface bonded to the second surface of the foam panel layer. The laminated architectural structure of claim 25, wherein the first structural layer of the roof component is a metal sheet layer. 26. The laminated architectural structure of claim 25, wherein the exterior surface of the first structural layer of the roof component coincides with the top surface of the roof component. The laminated architectural structure of claim 25, wherein the second structural layer of the roof component is a metal sheet layer. 26. The laminated architectural structure of claim 25, wherein the roof component further comprises a protective layer having a first surface and an opposing second surface, the first surface of the protective layer being adhered to the opposing second surface of the second structural layer. The laminated architectural structure of claim 24, wherein the protective layer is made of MgO. The laminated architectural structure of claim 29, wherein the protective layer is made of MgO. A folded building structure that can be transported to a location where construction is desired,
(a) a fixed space portion including a planar, rectangular first floor portion having first and second longitudinal floor ends, first and second transverse floor ends, and a thickness, the first floor portion having, in the direction of the thickness, (i) a first structural layer having a first side and an opposing second side, (ii) a foam panel layer having a first side and an opposing second side, the first side of the foam panel layer being bonded to the opposing second side of the first structural layer, (iii) a second structural layer having a first side and an opposing second side, the first side of the second structural layer being bonded to the opposing second side of the foam panel layer, and (iv) a first end reinforcement adjacent the first longitudinal floor end and a second end reinforcement adjacent the second longitudinal floor end;
(b) the first floor portion has between the first structural layer and the second structural layer: (i) a first fork tube oriented in a transverse direction and spanning a distance from the first longitudinal floor end to the second longitudinal floor end to define a first opening at the first longitudinal floor end and a second opening at the second longitudinal floor end; (ii) a first fork tube plate that is planar, elongated, longitudinally oriented and secured to the first end reinforcement and the first fork tube; and (iv) a second fork tube plate that is planar, elongated, longitudinally oriented and secured to the second end reinforcement and the first fork tube. 33. The folded architectural structure of claim 32, wherein the first floor portion further comprises: (ii) a second fork tube between the first structural layer and the second structural layer, the second fork tube being oriented in a transverse direction and spaced apart from the first fork tube to span the distance from the first longitudinal floor end to the second longitudinal floor end so as to define a third opening at the first longitudinal floor end and a fourth opening at the second longitudinal floor end; (ii) a planar, elongated, longitudinally oriented third fork tube plate secured to the first end reinforcement and the second fork tube; and (iv) a planar, elongated, longitudinally oriented fourth fork tube plate secured to the second end reinforcement and the first fork tube. 34. The folded architectural structure of claim 33, wherein the first fork tube plate extends beyond the first fork tube in a direction away from the second fork tube along the first end reinforcement, and the third fork tube plate extends beyond the second fork tube in a direction opposite to the direction away from the first fork tube along the first end reinforcement. The folded architectural structure of claim 33, wherein the second fork tube plate extends beyond the first fork tube in a direction away from the second fork tube along the second end reinforcement, and the fourth fork tube plate extends beyond the second fork tube in a direction opposite to the direction away from the first fork tube along the second end reinforcement. The folded architectural structure of claim 33, wherein the first structural layer of the floor section is a metal sheet layer. The folded architectural structure of claim 33, wherein the first and second fork tubes have a rectangular cross section. The folded architectural structure of claim 37, wherein the first and second fork tubes are in contact with the first structural layer. (d) a planar, rectangular second floor section having third and fourth longitudinal floor edges, third and fourth transverse floor edges, and a thickness, the second floor section having a laminated construction across the thickness, the second floor section having (i) a first structural layer having a first side and an opposing second side, (ii) a foam panel layer having a first side and an opposing second side, the first side of the foam panel layer being adhered to the opposing second side of the first structural layer, and (iii) a second structural layer having a first side and an opposing second side, the first side of the second structural layer being adhered to the opposing second side of the foam panel layer;
(f) the second floor section has means for pivotally connecting the floor section to the second floor section so as to enable angular rotation about a horizontal axis proximate the second and third longitudinal floor ends, said angular rotation being from a second floor section folded position oriented at an angle relative to the first floor section to an unfolded position of the second floor section coplanar with the first floor section. The folded architectural structure of claim 32. A folded building structure that can be transported to a location where construction is desired,
(a) a fixed space portion including a planar, rectangular first floor portion having first and second longitudinal floor ends, first and second transverse floor ends, and a thickness, the first floor portion having a laminated structure having, in the thickness direction, (i) a first structural layer having a first surface and an opposing second surface, (ii) a foam panel layer having a first surface and an opposing second surface, the first surface of the foam panel layer being bonded to the opposing second surface of the first structural layer, (iii) a second structural layer having a first surface and an opposing second surface, the first surface of the second structural layer being bonded to the opposing second surface of the foam panel layer, and (iv) a first end reinforcement adjacent the first longitudinal floor end and a second end reinforcement adjacent the second longitudinal floor end;
(b) a first beam reinforcing the laminated structure and oriented transversely, the first beam having a first end disposed adjacent the first longitudinal floor edge and a second end disposed adjacent the second longitudinal floor edge;
(c) the first floor section has, between the first structural layer and the second structural layer, (i) a first fork tube oriented in the transverse direction and spaced from a first side of the first beam, the first fork tube spanning a distance from the first longitudinal floor end to the second longitudinal floor end to define a first opening at the first longitudinal floor end and a second opening at the second longitudinal floor end, (ii) a first fork tube plate arranged relative to the first end reinforcement and secured to the first end reinforcement and the first fork tube, the first fork tube plate having a longitudinal length spanning the distance between the first fork tube and the first beam, and (iv) a second fork tube plate arranged relative to the second end reinforcement and secured to the second end reinforcement and the first fork tube, the second fork tube plate having a longitudinal length spanning the distance between the first fork tube and the first beam.
Folded architectural structure. 41. The folded architectural structure of claim 40, wherein the first floor portion further comprises: (ii) a second fork tube between the first structural layer and the second structural layer, oriented transversely and spaced from a second side of the first beam opposite the first side, the second fork tube spanning the distance from the first longitudinal floor end to the second longitudinal floor end to define a third opening at the first longitudinal floor end and a fourth opening at the second longitudinal floor end; (ii) a planar, elongated, longitudinally oriented third fork tube plate secured to the first end reinforcement and the second fork tube, the third fork tube plate having a longitudinal length spanning the distance between the second fork tube and the first beam; and (iv) a planar, elongated, longitudinally oriented fourth fork tube plate secured to the second end reinforcement and the first fork tube, the fourth fork tube plate having a longitudinal length spanning the distance between the second fork tube and the first beam. The folded architectural structure of claim 41, wherein the first fork tube plate extends beyond the first fork tube in a direction away from the first beam along the first end reinforcement, and the third fork tube plate extends beyond the second fork tube in a direction opposite to the direction away from the first beam along the first end reinforcement. The folded architectural structure of claim 41, wherein the second fork tube plate extends beyond the first fork tube in a direction away from the first beam along the second end reinforcement, and the fourth fork tube plate extends beyond the second fork tube in a direction opposite to the direction away from the first beam along the second end reinforcement. The folded architectural structure of claim 40, wherein the first structural layer of the floor section is a metal sheet layer. The folded architectural structure of claim 44, wherein the first and second fork tubes are rectangular in cross section. The folded architectural structure of claim 45, wherein the first and second fork tubes are in contact with the first structural layer. (d) a planar, rectangular second floor section having third and fourth longitudinal floor edges, third and fourth transverse floor edges, and a thickness, the second floor section having a laminated construction across the thickness, the second floor section having (i) a first structural layer having a first side and an opposing second side, (ii) a foam panel layer having a first side and an opposing second side, the first side of the foam panel layer being adhered to the opposing second side of the first structural layer, and (iii) a second structural layer having a first side and an opposing second side, the first side of the second structural layer being adhered to the opposing second side of the foam panel layer;
(e) a second beam reinforcing the laminated structure of the second floor section and oriented transversely, the second beam having a third end disposed adjacent the third longitudinal floor end and a fourth end disposed adjacent the fourth longitudinal floor end;
(f) the third end of the second beam is pivotally connected to the second end of the first beam so that the second floor section can be angularly rotated about a horizontal axis proximate to the second and third longitudinal floor ends, said angular rotation being from a second floor section folded position oriented at an angle to the first floor section to an unfolded position of the second floor section coplanar with the first floor section. The folded architectural structure of claim 33, wherein the second fork tube is a metal sheet layer. The folded architectural structure of claim 33, wherein each of the third and fourth fork tube plates is made of metal. The folded architectural structure of claim 32, wherein the first fork tube is made of metal. The folded architectural structure of claim 32, wherein each of the first and second fork tube plates is made of metal. The folded architectural structure of claim 51, wherein the metal is steel. The folded architectural structure of claim 32, wherein each of the first and second end reinforcements is laminated strand lumberboard.

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