US20200332512A1

US20200332512A1 - Foldable building system and methods of use

Info

Publication number: US20200332512A1
Application number: US16/798,294
Authority: US
Inventors: Frederick Smith; Nick Kupresin; Thomas Waggoner
Original assignee: Fastpaks LLC
Current assignee: Fastpaks LLC
Priority date: 2019-02-21
Filing date: 2020-02-21
Publication date: 2020-10-22

Abstract

Various embodiments provide a flat pack structure configured to be stored and shipped in a stacked configuration having the roof and a pair of side walls stacked onto the base. The flat pack structure is configured to be transformed from the stacked or folded configuration into a built configuration, then reduced from the built configuration back into the stacked or folded configuration.

Description

RELATED APPLICATIONS

This patent application claims the benefit of and priority to US Provisional Patent Application 62/808,438 filed Feb. 21, 2019, which is incorporated by reference herein.

BACKGROUND

Flat pack furniture is a well-known form of furniture that requires customer assembly. For example, U.S. Pat. No. 1,824,243 entitled Knock-down Furniture Structure was issued Sep. 22, 1931.
Also known as ready-to-assemble furniture, the separate components are packed in cartons which also contain assembly instructions. The furniture is generally simple to assemble with basic tools such as screwdrivers, which are also sometimes included.
More recently, flat pack building structures are designed in which wall and roof components are stacked and packaged for shipping. After such a flat pack building structure is received on site, it must be unpackaged then each of the wall and roof components are placed on a foundation and assembled. Assembly of such building structures is less time consuming then building a structure from scratch. Once assembled, such a building structures cannot be dissembled and then moved to another location.
Typically, intermodal shipping containers can typically be disassembled to be shipped back in a flat format to save space on freighters. In some cases, the one of the side walls of the container may fold inward, however, the top panel must first be removed, which may require a crane. The same goes for re-assembly, a crane maybe needed to install the top panel. There have attempts to repurpose such intermodal shipping containers for portable buildings. Since the containers are built out of 4 tons of steel, cranes are needed to move and rebuild the containers and outer surface configurations are fixed do to the steel sides.
New systems and methods are thus needed which overcome these limitations. Various desirable features and characteristics will also become apparent from the subsequent detailed description and the claims, taken in conjunction with the accompanying drawings and this background section.

SUMMARY

Various embodiments provide a flat pack structure, which can be a foldable building system. The foldable building system is configured to move between a folded configuration to a built configuration without disassembling any of the side walls from the base or disassembling the roof panels from the side walls. In addition, the foldable building system is configured to move between a built configuration to a folded configuration without disassembling any of the side walls from the base or disassembling the roof panels from the side walls.
Various embodiments provide methods of use of a foldable building system. Moving from a built foldable building system to a folded configuration, a method can include the steps of folding a side wall in onto a base then rotating an attached roof panel and placing the roof panel on top of the side wall. The method can further include the steps of folding an opposite side wall onto the roof panel then rotating an attached opposite roof panel and placing the opposite roof panel on top of the opposite side wall.
Moving from a folded foldable building system to the built configuration, a method can include the steps of unfolding a side wall and attached roof panel and placing the side wall perpendicular to a base, then unfolding an opposite side wall and attached opposite roof panel and placing the opposite side wall perpendicular to the base. The method can further include the steps of rotating the roof panel toward a center point of the structure then rotating the opposite roof panel toward the center point of the structure and connecting the roof panel and the opposite roof panel at a peak of the structure. In some variations, the method can include the steps of locking the side wall and the opposite side wall orthogonally to the base.

DRAWINGS

The present disclosure will become more fully understood from the description and the accompanying drawings, wherein:

FIG. 1 is a perspective exploded view of exemplary components of a foldable building system, in accordance with various embodiments

FIG. 2 is a perspective view of a foldable building system in a built configuration, in accordance with various embodiments;

FIG. 3 is a top planar view of the foldable building system of FIG. 2, in accordance with various embodiments;

FIG. 4 is a bottom planar view of the foldable building system FIG. 2, in accordance with various embodiments;

FIG. 5 is a side view of the foldable building system of FIG. 2, in accordance with various embodiments;

FIG. 6 is a detailed view of a corner wrapper in Box 6 of FIG. 5, in accordance with various embodiments;

FIG. 7 is a detailed view of a corner wrapper in Box 7 of FIG. 5, in accordance with various embodiments;

FIG. 8 is an end on view of the foldable building system of FIG. 2, in accordance with various embodiments;

FIG. 9 is a detailed view of a corner wrapper in Box 9 of FIG. 8, in accordance with various embodiments;

FIG. 10 is a detailed view of a corner wrapper in Box 10 of FIG. 8, in accordance with various embodiments;

FIG. 11 is a perspective view of a corner wrapper, in accordance with various embodiments;

FIG. 12 is detailed view of a hinge in Circle 12 of FIG. 8, in accordance with various embodiments;

FIG. 13 is a perspective cross-sectional view of the foldable building system of FIG. 2 along the line 13-13 of FIG. 3, in accordance with various embodiments;

FIG. 14 is a perspective view of a foldable building system of FIG. 2 in a folded configuration, in accordance with various embodiments;

FIG. 15 is a top planar view of the foldable building system of FIG. 14, in accordance with various embodiments;

FIG. 16 is a bottom planar view of the foldable building system of FIG. 14, in accordance with various embodiments;

FIG. 17 is a side view of the foldable building system of FIG. 14, in accordance with various embodiments;

FIG. 18 is a detailed view of a corner wrapper in Box 18 of FIG. 17, in accordance with various embodiments;

FIG. 19 is a detailed view of a corner wrapper in Box 19 of FIG. 17, in accordance with various embodiments;

FIG. 20 is a front view of the foldable building system of FIG. 14, in accordance with various embodiments;

FIG. 21 is detailed view of a corner wrapper in Box 21 of FIG. 20, in accordance with various embodiments;

FIG. 22 is detailed view of a corner wrapper in Box 22 of FIG. 20, in accordance with various embodiments;

FIG. 23 is a perspective cross-sectional view of the foldable building system of FIG. 14 along the line 23-23 of FIG. 15, in accordance with various embodiments;

FIG. 24 is an end on view of a foldable building system illustrating a step of a method, in accordance with various embodiments;

FIG. 25 is an end on view of a foldable building system illustrating a step of a method, in accordance with various embodiments;

FIG. 26 is an end on view of a foldable building system illustrating a step of a method, in accordance with various embodiments;

FIG. 27 is detailed view of a corner wrapper in Circle A of FIG. 26, in accordance with various embodiments;

FIG. 28 is an end on view of a foldable building system illustrating a step of a method, in accordance with various embodiments;

FIG. 29 is detailed view of a corner wrapper in Circle C of FIG. 28, in accordance with various embodiments; and

FIG. 30 is perspective of an application of a foldable building structure configured as a greenhouse, in accordance with various embodiments.

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of any of the exemplary embodiments disclosed herein or any equivalents thereof. It is understood that the drawings are not drawn to scale. Hashed lines indicate an optional element or method step. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements.

DESCRIPTION

The following description is merely exemplary in nature and is in no way intended to limit the exemplary embodiments, their application, or uses. The steps within a method may be executed in different order without altering the principles of the present disclosure. For example, various embodiments may be described herein in terms of various functional components and processing steps. It should be appreciated that such components and steps may be realized by any number of hardware components configured to perform the specified functions.
Various embodiments provide a flat pack structure configured to be stored and shipped in a stacked configuration having the roof and a pair of side walls stacked onto the base. The flat pack structure is configured to be transformed from the stacked (or folded) configuration into a built configuration, then reduced from the built configuration back into the stacked (or folded) configuration. The flat pack structure can be a foldable building system.
The built configuration can further comprise plurality of sheathing components, which can be configured to encase the structure to protect the inside area from the elements outside the structure. The sheathing components can be attached to the side walls and/or the roof. The sheathing components can remain attached to the side walls and roof while the built configuration is reduced to the stacked configuration. Alternatively, the plurality of sheathing components can be stacked on top of the stacked configuration of the flat pack structure. The built configuration can comprise a front wall and a back wall, which further can comprise sheathing components attached thereto.
In some embodiments, the flat pack structure can comprise a base, a pair of side walls each coupled to the base, and a pair of roof panels, each roof panel coupled to one of the side walls. The base can comprise corners, which have a slot that is positioned above a floor plane of the base and orthogonal to the floor plane of the base. Each side wall can comprise a pair of pins on toward the bottom of the side wall, which are distal to each other. The pins engage the slots at opposite corners of the base thus coupling the side walls to the base. The pins are permanently engaged in the slots thus the side walls cannot be uncoupled from the base. The pins can both move up and down in the slots and rotate within the slots.
Various embodiments provide a foldable building system, as illustrated in FIG. 1. The foldable building system 100 comprises a base 105, a first side wall 115, a first roof panel 117, a second side wall 116 and a second roof panel 118. The first side wall 115 is coupled to the base 105 and is coupled to the first roof panel 117 with a first pair of hinges 120. The second side wall 116 is coupled to the base and is coupled to a second roof panel 118 with a second pair of hinges 120. In other words, the base 105, the first side wall 115, the first roof panel 117, the second side wall 116 and the second roof panel 118 are attached to each other and the foldable building system 100 is a single unit.
The foldable building system 100 is configured to move between a folded configuration to a built configuration without disassembling any of the base 105, the first side wall 115, the first roof panel 117, the second side wall 116, or the second roof panel 118 from each other. Moving from the built to the folded configuration, the first side wall 115 is folded in onto the base 105 then the first roof panel 117 is rotated and placed on top of the first side wall 115; the second side wall 116 is folded in onto the first roof panel 117 then the second roof panel 118 is rotated and placed on top of the first side wall 115, as further discussed herein. However, an alternative folded configuration can have the components stacked in the opposite order. For example, the second side wall 116 is folded in onto the base 105 then the second roof panel 118 is rotated and placed on top of the second side wall 116; the first side wall 115 is folded in onto the second side wall 116 then the first roof panel 117 is rotated and placed on top of the first side wall 115.
Moving from the folded configuration to the built configuration, the second side wall 116 is unfolded and placed perpendicular to base 105 then the first side wall 115 is unfolded and placed perpendicular to base 105; the first roof panel 117 and the second roof panel 118 are rotated until they meet at a peak then are fastened together. Moving from an alternative folded configuration to the built configuration, the first side wall 115 is unfolded and placed perpendicular to the base 105 then the second side wall 116 is unfolded and placed perpendicular to the base 105; the first roof panel 117 and the second roof panel 118 are rotated until they meet at a peak then are fastened together. Additional crossbeams can be added to the foldable building structure 100 for structural support. Sheathing can be added to encase the foldable building structure 100, as further discussed herein. In addition, a floor, internal walls, wiring, and plumbing can be added to the foldable building system 100, as needed.
The base 105 comprises four corner wrappers 110, each corner wrapper 110 positioned around an outside portion of each corner on the base 105. Each of the corner wrappers 110 comprises a slot 11, which is closed and located on the face of the foldable building system 100. The slot 111 is perpendicular to and positioned above the base 105.
The first side wall 115 and the second side wall 116 each comprise a pair of pins 112 located in opposite corners of each of the walls 115, 116. Each pin 112 is configured to move up and down, as well as, rotate inside of the slot 111 of the corner wrapper 110. During construction of the foldable building system 100, the first side wall 115 is placed on base 105 then the corner wrappers 105 engage the pins 112 on either side of the first side wall 115 via the slots 111 then the corner wrapper 110 is welded to the corners of the base 105. The process is followed for the second side wall 116. After the pins 112 are engaged in the slots 112 and the corner wrappers 110 are welded to the base 105, the side walls 115, 116 are permanently coupled to the base 105. Since the pins 112 are moveably engaged in the slots 111, the side walls 115, 116 can be folded toward the base 105 and are limited being perpendicular to the base 105 when unfolded.
In some embodiments, the first side wall 115 and the second side wall 116 are frames. Each of the side walls 115, 116 can be a frame comprising a plurality of cross beams or studs. Each of the side walls 115, 116 can be a frame that is perforated, such as, for example, honeycombed or corrugated. Each of the side walls 115, 116 can be a frame with sheathing attached. The side walls 115, 116 can comprise a series of holes configured to receive fasteners, which secure sheathing panels to the side walls 115, 116. In some configurations, the side walls 115, 116 can be solid.
The hinge 120 comprises a pair of fasteners 121 and a hinge bracket 122. One of the fasteners 121 is configured to go through one end of the hinge bracket 122 and connect into a side wall. The other fasteners 121 is configured to go through a distal end of the hinge bracket 122 and connect into a roof panel. The pair of fasteners 121 are fixed and the hinge bracket 122 rotates around the fasteners 121. A fastener 121 can be a bolt, a screw, a rivet, or any other such fastener, now known or developed in the future. Alternatively, the fastener 121 can be a multi-piece system, such as, a stud with a cap, a threaded stud with a bolt, any fastener with one or more washers, or any other appropriate multi-piece fastener, now known or developed in the future.
The first roof portion 117 and second roof panels 118 are configured to meet at a peak then coupled together. One of the roof panels 117,118 can be wider than the other and configured to be placed over the other at the peak. Such a configuration can add stability to the roof structure and can allow for better access points to fasten the roof panels 117, 118 together at the peak. In some embodiments, the first roof panel 117 and second roof panel 118 are frames. Each of the roof portions 117, 118 can be a frame comprising a plurality of cross beams or studs. Each of the roof portions 117, 118 can be that is perforated, such as, for example, honeycombed or corrugated. Each of the roof panels 117, 118 can be a frame with roofing material attached. The roof portions 117, 118 can comprise a series of holes configured to receive fasteners, which secure sheathing panels to the roof portions 117, 118. In some configurations, the roof portions 117, 118 can be solid.
Now referring to FIGS. 2-13, various embodiments of a foldable building system 200 is illustrated in a built configuration. FIG. 2 is a perspective view of the foldable building system 200 in a built configuration. FIG. 3 is a top planar view of the foldable building system 200. FIG. 4 is a bottom planar view of the foldable building system 200. FIG. 5 is a side view of the foldable building system 200 representing both sides of the system 200, which are essentially equivalent. FIG. 8 is an end on view of the foldable building system 200 representing both the front end and the back end, which are essentially equivalent.
The foldable building system 200 comprises a base 205, a wall 215, a roof panel 217, an opposite wall 216 and an opposite roof panel 218. The wall 215 is coupled to the base 205 and is coupled to the roof panel 217 with a pair of hinges 220. The opposite wall 216 is coupled to the base 205 and is coupled to the opposite roof panel 218 with another pair of hinges 220. The foldable building system 200 can comprise a frame unit 250. In some configurations, the frame unit 250 comprises a plurality of components, which remain coupled together in a folded configuration and as the system 200 moves into the built configuration then from the built configuration as the system 200 moves back to the folded configuration. Accordingly, the frame unit 250 can comprise the roof panel 217 coupled to the wall 215, which is coupled to the base 205 and the opposite wall 216 coupled to the base 205 and the opposite roof panel 218 coupled to the opposite wall 216.
As illustrated in FIGS. 2 and 8, the foldable building system 200 comprises the frame unit 250 and a pair of gable panels 224 attached to the frame unit 250. In addition, the foldable building system 200 comprises a pair of upper crossbeams 226, each connected to the wall 215 and the opposite wall 216, as well as to the gable panel 224. The foldable building system 200 comprises a pair of lower crossbeams 227, each connected to the wall 215 and the opposite wall 216, as well as the base 205. The foldable building system 200 comprises a pair of stud beams 225, each connecting to the upper crossbeam 226 and the lower crossbeam 227. The foldable building system 200 can comprise a pair peak brackets 228, which couple the roof panel 217 and the opposite roof panel 218 together at the peak 230.
Moving to FIG. 3, each of the roof panels 217, 218 can be configured as a frame comprising a top beam 234, a bottom beam 235, a pair of end beams 236, 237, and a plurality of studs 238.
As illustrated in FIG. 4, the base 205 can be configured as a frame comprising a pair of end beams 244, 245, a pair of side beams 246, 247, and a plurality of cross beams 248. The base 205 can include flooring, such as, for example, three-quarter inch plywood. Of course, the flooring can be any appropriate material to fit an application for which the foldable building structure 200 is being deployed. The base 205 can include a plurality of flanges 222 coupled to the side beams 246, 247. The plurality of flanges 222 can be configured to secure the foldable building system 200 in a folded configuration onto a flat-bed trailer or other transportation mechanism. The plurality of flanges 222 can be configured to secure the foldable building system 200 in the built configuration to the ground, to a cement pad, or any other foundation or substrate. The base 205 include four corner wrappers 210 positioned on the four corners of the base 205.
As illustrated in FIG. 5, each of the walls 215, 216 can be configured as a frame comprising a top beam 252, a bottom beam 253, a pair of end beams 254, 255, and a plurality of studs 256. Each of the walls 215, 216 comprise pins 212 on each of the end beams 254, 255 at or near the bottom beam 253. In some configurations, each of the walls 215, 216 comprise locking pins 258 on each of the end beams 254, 255, which are located above the pins 212 in relations to the bottom beam 253.
FIGS. 5-11 illustrate various embodiments of the corner wrapper 210 of the foldable building system 200 in the built configuration. FIG. 6 is a detailed view of the corner wrapper 210 in Box 6 of FIG. 5. FIG. 7 is a detailed view of the corner wrapper 210 in Box 7 of FIG. 5. FIG. 9 is a detailed view of the corner wrapper 210 in Box 9 of FIG. 8. FIG. 10 is a detailed view of the corner wrapper 210 in Box 10 of FIG. 8. FIG. 11 is a perspective view of an exemplary corner wrapper 210.
Each corner wrapper 210 is positioned around an outside portion of each corner on the base 205. The corner wrapper 210 comprises a slot 211, which is closed and located on a wrapper face 265 of the foldable building system 200. The slot 211 is perpendicular to and positioned above the base 205.
The wrapper face 265 is orthogonal to one of the walls 216, 217. A wrapper side 266 is parallel to one of the walls 216, 217. A wrapper face leg 267 is orthogonal to one of the walls 216, 217 and is parallel to one of the end beams 244, 245 of the base 205. A wrapper side leg 268 is parallel to one of the walls 216, 217 and is parallel to one of the side beams 246, 247 of the base 205.
The wrapper face leg 267 is coupled to one of the end beams 244, 245 of the base 205. The wrapper side leg 268 is coupled to one of the side beams 246, 247 of the base 205. As known to one skilled in the art, the wrapper face 267 and wrapper side leg 268 can be coupled to the base using any of a variety of methods, such as, for example, welding, fusing, adhesives, fasteners, stamping, molding, or combinations thereof. Examples of applicable fasteners can include, but are not limited to rivets, nuts and bolts, screw, or any or any other such fastener, now known or developed in the future. In some configurations, the wrapper face 267 and wrapper side leg 268 are welded to the base 205. In some configurations, the wrapper face 267 and wrapper side leg 268 are coupled to the base 205 with one or more fasteners. Of course, the wrapper leg 267 and wrapper side leg 268 can be both welded and fastened to the base 205.
Each of the walls 215, 216 comprise a pair of pins 212 located in opposite corners of each of the walls 215, 216. Each pin 112 is configured to up and down, as well as, rotate inside of the slot 211 of the corner wrapper 210.
During construction of the foldable building system 200, the first side wall 215 is placed on base 205 then the corner wrappers 205 engage the pins 212 on either side of the wall 215 via the slots 211 and the corner wrapper 210 is welded to the corners of the base 205. The process is followed for the second side wall 216. After the pins 212 are engaged in the slots 212 and the corner wrappers 210 are welded to the base 205, the side walls 115, 116 are permanently coupled to the base 205. Since the pins 212 are moveably engaged in the slots 211, the side walls 215, 216 can be folded toward the base 205 and are limited to being perpendicular to the base 205 when unfolded.
Each of the walls 215, 216 comprise a pair of locking pins 336 located on opposite sides of each of the side walls 215, 216. Each corner wrapper 210 comprise a locking notch 269 at the top of the corner wrapper 310. The locking notch 269 is configured to engage a locking pin 236, which secures a side wall in the corner wrapper 210.
The first side wall 215 is coupled to the base 205 and is coupled to the first roof panel 217 with a first pair of hinges 220. The second side wall 216 is coupled to the base and is coupled to a second roof panel 218 with a second pair of hinges 220. FIG. 12 is detailed view of a hinge 220 in Circle 12 of FIG. 8.
The hinge 220 comprises a pair of fasteners 221 and a hinge bracket 222. One of the fasteners 221 is configured to go through one end of the hinge bracket 222 and connect into a side wall. The other fasteners 221 is configured to go through a distal end of the hinge bracket 222 and connect into a roof panel. The pair of fasteners 221 are fixed and the hinge bracket 222 rotates around the fasteners 221. A fastener 221 can be a bolt, a screw, a rivet, or any other such fastener, now known or developed in the future. Alternatively, the fastener 221 can be a multi-piece system, such as, a stud with a cap, a threaded stud with a bolt, any fastener with one or more washers, or any other appropriate multi-piece fastener, now known or developed in the future.
Each hinge 220 comprises two pivot points. A first pivot point rotates (as indicated by arrow 276) around the fastener 221 of the roof panel 217. A second pivot point rotates (as indicated by arrow 278) around the fastener 221 of the side wall 215. roof panel 217
Turning to FIG. 13, a perspective cross-sectional view of the foldable building system 200 of FIG. 2 is illustrated along the line 13-13 of FIG. 3.
Now with reference to FIGS. 14-22, various embodiments of the foldable building system 200 in a folded configuration are disclosed. The reference numbers included in these figures are described in detail above.
FIG. 14 is a perspective view of a foldable building system of FIG. 2 in a folded configuration.
FIG. 15 is a top planar view of the foldable building system of FIG. 14.
FIG. 16 is a bottom planar view of the foldable building system of FIG. 14.
FIG. 17 is a side view of the foldable building system of FIG. 14.
FIG. 18 illustrates the details of the corner wrapper 310 of Box 18 of FIG. 17.
FIG. 19 illustrates the details of the corner wrapper 310 of Box 19 of FIG. 17.
FIG. 21 illustrates the details of the corner wrapper 310 of Box 21 of FIG. 20.
FIG. 22 illustrates the details of the corner wrapper 310 of Box 22 of FIG. 20.
Turning to FIG. 23, a perspective cross-sectional view of the foldable building system of FIG. 14 is illustrated along the line 23-23 of FIG. 15.
In accordance with the various embodiments, disclosed herein, a foldable building system is configured to move between a folded configuration to a built configuration without disassembling any of the side walls from the base or disassembling the roof panels from the side walls, as discussed herein. In addition, the foldable building system is configured to move between a built configuration to a folded configuration without disassembling any of the side walls from the base or disassembling the roof panels from the side walls.
Various embodiments provide methods of use of a foldable building system.
Moving from a built foldable building system to a folded configuration, a method can include the steps of folding a side wall in onto a base then rotating an attached roof panel and placing the roof panel on top of the side wall. The method can further include the steps of folding an opposite side wall onto the roof panel then rotating an attached opposite roof panel and placing the opposite roof panel on top of the opposite side wall.
Moving from a folded foldable building system to the built configuration, a method can include the steps of unfolding a side wall and attached roof panel and placing the side wall perpendicular to a base, then unfolding an opposite side wall and attached opposite roof panel and placing the opposite side wall perpendicular to the base. The method can further include the steps of rotating the roof panel toward a center point of the structure then rotating the opposite roof panel toward the center point of the structure and connecting the roof panel and the opposite roof panel at a peak of the structure. In some variations, the method can include the steps of locking the side wall and the opposite side wall orthogonally to the base.
FIGS. 24-29 illustrate exemplary steps for various methods of use of a foldable building structure 300. The foldable building structure 300 is substantially similar to the foldable building structure 100 and/or the foldable building structure 200, described herein.
The foldable building structure 300 can comprise a base 305 and corner wrappers 310 coupled to the corners of the base 305. A first wall 315 is coupled to a first roof panel 317 by a hinge 320 and the first wall 315 is coupled to one of the corner wrappers 310. A second wall 316 is coupled to a second roof panel 318 by another hinge 320 and the second wall 316 is coupled to one of the corner wrappers 310.
In addition, the foldable building system 300 comprises a stud beam 325 connecting to an upper crossbeam 326 and a lower crossbeam 327. A pair peak brackets 328 can be coupled together at a peak 330 and then coupled to the first wall 315 and the second wall 317. The pair peak brackets 328 can be coupled to each of the first roof panel 317 and the second roof panel 318.
As illustrated in FIG. 24, the hinge 320 is utilized to rotate (as indicated by arrow 371) the first roof panel 317. After the rotation, the first roof panel 317 can be substantially parallel to the first wall 315. After the rotation, the first roof panel 317 can be in contact with the first wall 315. Similarly, the other hinge 320 is utilized to rotate (as indicated by arrow 371) the second roof panel 318. After this rotation, the second roof panel 318 can be substantially parallel to the second wall 316. After the rotation, the second roof panel 318 can be in contact with the second wall 316. Of course, the second roof panel 318 can be rotated first and the first roof panel 317 can be rotated second.
As illustrated in FIG. 25, the upper crossbeam 326 and the pair peak brackets 328 are removed from the foldable building structure 300.
Moving to FIG. 26, the first wall 315 is lifted orthogonally (as indicated by arrow 372) to the base 305, which is limited by movement of a pin 312 along slot 311 of the corner wrapper 310. The first wall 315 is lifted high enough to disengage a locking pin 336 from locking insert 369. Then the first wall 315 is rotated (as indicated by arrow 373) around pin 312 as limited by the slot 311 and set onto the base 305. FIG. 27 illustrates the details of the corner wrapper 310 in Circle A of FIG. 26.
Turning to FIG. 28, the second wall 316 is lifted orthogonally (as indicated by arrow 372) to the base 305, which is limited by movement of a pin 312 along slot 311 of the corner wrapper 310. The second wall 316 is lifted high enough to disengage a locking pin 336 from locking insert 369. Then the second wall 316 is rotated (as indicated by arrow 373) around pin 312 as limited by the slot 311 and set onto the first roof panel 317. FIG. 29 illustrates the details of the corner wrapper 310 in Circle C of FIG. 28.
Finally, FIG. 30 illustrates an application of the foldable building system as a greenhouse. Foldable greenhouse 400 comprises the structure of the foldable building system 100 or foldable building structure 200, as described herein. Foldable greenhouse further comprises a plurality of clear sheathing 402 encasing the foldable building structure. The clear sheathing 402 can comprise a door (not shown) and various openings configured as vents or utility feeds (also not shown). In some embodiments, the clear sheathing 402 is polycarbonate.
In some applications, the roof structure includes moveable vent panels (not shown). The moveable vent panels can be manually opened or opened with a motor. The moveable vent panels can be automated to open based on a timer and/or based on humidity.
In FIG. 30, the foldable greenhouse 400 is shown in a built configuration, which is encased with a clear sheathing 402. Further, the foldable greenhouse 400 contains plants 404. The greenhouse 400 comprising the plants 404 can be lifted by a forklift onto a flatbed trailer 405 to be transported to a different location without removing the plants 404.
In some applications, the foldable building system can be encased with solid panels. These solid panels will be configured as a totally solid panel, a panel with a window, a panel with a door or combinations thereof. All panels can have the same dimensions and can be easily interchanged. The panels can be constructed of a sheet metal skin, which can include insulated backing to meet environmental demands. The foldable building structure can be configured with plumbing, electrical features, HVAC, enhanced flooring, and combinations thereof.
In another application the foldable building system can be configured as a guard shack. For example, the foldable building structure can be encased with panels comprising ballistic protection. This ballistic protection could take several forms. One option could utilize a plaster-like substance called BallisiCrete that is applied on site. BallisiCrete has ceramic like strength and hardness qualities that are designed to stop all handgun bullets and most rifle bullets, even armor piercing. Another option could utilize a type of high-tech fiber with advanced polymers that creates an engineered fabric that provides strength and energy absorption. The process involves laminating multiple fiber layers in an engineered construction. Still another option could be a type of metallic type ballistic protection commonly used by our military, such as high hard steel.
In some applications, multiple foldable building structures can be connected to each other to form a larger structure. For example, four building structures can be connected in a rectangle. In such a configuration, the cross beams of the interior walls are not included, and interior space is encumbered a single post, which is the intersection of the four building structures. In another example, multiple foldable building structures can be laid out in a hamster configuration, which comprises groups of the building structures set up as larger rooms that are connected one of more of the building structures set linearly to operate all hallways between the larger rooms. Of course, any number of foldable building structures can set in any configuration, as needed by any application.
Various embodiments provide a foldable building system comprising: a base; a pair of side walls, each of the side walls coupled to the base; and a pair of roof panels, each roof panel coupled to one of the side walls. The folding building system can further comprise four corner members coupled to the base, each corner member comprising a slot positioned above a floor plane of the base and orthogonal to the floor plane of the base.
The folding building can further comprise a pair of pins configured to engage the slots at opposite corners of the base, the pair of pins integrated into the side wall and positioned distal to each other. The pins can be configured to couple the side walls to the base. The pins can be permanently engaged in the slots, whereby the side wall cannot be uncoupled from the base. The pins can be configured to move up and down in the slots and are configured to rotate within the slots.
In various embodiments, the foldable building system is configured to move between a folded configuration to a built configuration without uncoupling the side wall from the base or uncoupling the roof panels from the side walls.
In various embodiments, the foldable building system is configured to move between a built configuration to a folded configuration without uncoupling the side wall from the base or uncoupling the roof panels from the side walls.
In various embodiments provide methods of folding a foldable building system. A method can comprising providing foldable building system comprising: a base; a pair of side walls, each of the side walls coupled to the base; and a pair of roof panels, each roof panel coupled to one of the side walls. The method can comprise folding a first side wall in onto a base; rotating a first roof panel coupled to the first side wall; placing the first roof panel on top of the first side wall; folding a second side wall onto the first roof panel; rotating a second roof panel coupled to the second side wall; and placing the second panel on top of the second side wall.
Various embodiments provide methods of erecting a foldable building system. A method can comprise providing foldable building system comprising: a base; a pair of side walls, each of the side walls coupled to the base; and a pair of roof panels, each roof panel coupled to one of the side walls. The method can comprise rotating a first side wall from a position parallel to the base, wherein the first side wall is coupled to a first roof panel; affixing the first side wall perpendicular onto the base; rotating a second side wall coupled to a second roof panel, wherein the second side wall is coupled to a second roof panel; affixing the second side wall perpendicular onto the base; wherein the second side wall faces the first side wall on distal sides of the base; rotating the first roof panel toward a center point between the first side wall and the second side wall; rotating the second roof panel toward the center point between the first side wall and the second side wall; and connecting the first roof panel to the second roof panel at the center point between the first side wall and the second side wall.
A roof peak is formed at the connection of the first roof panel to the second roof panel at the center point between the first side wall and the second side wall. The method can further comprise locking the first side wall and the second side wall orthogonally onto the base.
As used herein, the phrase “at least one of A, B, and C” can be construed to mean a logical (A or B or C), using a non-exclusive logical “or,” however, can be contrasted to mean (A, B, and C), in addition, can be construed to mean (A and B) or (A and C) or (B and C). As used herein, the phrase “A, B and/or C” should be construed to mean (A, B, and C) or alternatively (A or B or C), using a non-exclusive logical “or.”
The present invention has been described above with reference to various exemplary embodiments and examples, which are not intended to be limiting in describing the full scope of systems and methods of this invention. However, those skilled in the art will recognize that equivalent changes, modifications and variations of the embodiments, materials, systems, and methods may be made within the scope of the present invention, with substantially similar results, and are intended to be included within the scope of the present invention, as set forth in the following claims.

Claims

1. A foldable building system comprising:

a base;

a pair of side walls, each of the side walls coupled to the base; and

a pair of roof panels, each roof panel coupled to one of the side walls.

2. The folding building system according to claim 1, further comprising four corner members coupled to the base, each corner member comprising a slot positioned above a floor plane of the base and orthogonal to the floor plane of the base.

3. The folding building system according to claim 2, further comprising a pair of pins configured to engage the slots at opposite corners of the base, the pair of pins integrated into the side wall and positioned distal to each other.

4. The folding building system according to claim 3, wherein the pins are configured to couple the side walls to the base.

5. The folding building system according to claim 3, wherein the pins are permanently engaged in the slots, whereby the side wall cannot be uncoupled from the base.

6. The folding building system according to claim 3, wherein the pins are configured to move up and down in the slots and are configured to rotate within the slots.

7. The foldable building system according to claim 1, wherein the foldable building system is configured to move between a folded configuration to a built configuration without uncoupling the side wall from the base or uncoupling the roof panels from the side walls.

8. The foldable building system according to claim 1, wherein the foldable building system is configured to move between a built configuration to a folded configuration without uncoupling the side wall from the base or uncoupling the roof panels from the side walls.

9. A method of folding a foldable building system, the method comprising:

providing foldable building system comprising:

a base;

a pair of side walls, each of the side walls coupled to the base; and

a pair of roof panels, each roof panel coupled to one of the side walls;

folding a first side wall in onto a base;

rotating a first roof panel coupled to the first side wall;

placing the first roof panel on top of the first side wall;

folding a second side wall onto the first roof panel;

rotating a second roof panel coupled to the second side wall; and

placing the second panel on top of the second side wall.

10. A method of erecting a foldable building system, the method comprising:

providing foldable building system comprising:

a base;

a pair of side walls, each of the side walls coupled to the base; and

a pair of roof panels, each roof panel coupled to one of the side walls;

rotating a first side wall from a position parallel to the base, wherein the first side wall is coupled to a first roof panel;

affixing the first side wall perpendicular onto the base;

rotating a second side wall coupled to a second roof panel, wherein the second side wall is coupled to a second roof panel;

affixing the second side wall perpendicular onto the base; wherein the second side wall faces the first side wall on distal sides of the base;

rotating the first roof panel toward a center point between the first side wall and the second side wall;

rotating the second roof panel toward the center point between the first side wall and the second side wall; and

connecting the first roof panel to the second roof panel at the center point between the first side wall and the second side wall.

11. The method according to claim 10, wherein a roof peak is formed at the connection of the first roof panel to the second roof panel at the center point between the first side wall and the second side wall.

12. The method according to claim 10, further comprising locking the first side wall and the second side wall orthogonally onto the base.