US20240018779A1 - Universal panel - Google Patents
Universal panel Download PDFInfo
- Publication number
- US20240018779A1 US20240018779A1 US18/220,333 US202318220333A US2024018779A1 US 20240018779 A1 US20240018779 A1 US 20240018779A1 US 202318220333 A US202318220333 A US 202318220333A US 2024018779 A1 US2024018779 A1 US 2024018779A1
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- Prior art keywords
- spline
- foam
- edge
- face
- structural
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000006260 foam Substances 0.000 claims abstract description 108
- 239000010410 layer Substances 0.000 claims description 49
- 239000012792 core layer Substances 0.000 claims description 48
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 19
- 239000000395 magnesium oxide Substances 0.000 claims description 19
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 19
- 239000004568 cement Substances 0.000 claims description 10
- 238000005304 joining Methods 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 description 10
- 230000002787 reinforcement Effects 0.000 description 10
- 239000000853 adhesive Substances 0.000 description 8
- 230000001070 adhesive effect Effects 0.000 description 8
- 238000010276 construction Methods 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 3
- 229920002635 polyurethane Polymers 0.000 description 3
- 239000004814 polyurethane Substances 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- 238000000638 solvent extraction Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 239000003818 cinder Substances 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 239000004794 expanded polystyrene Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000011496 polyurethane foam Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 241001669679 Eleotris Species 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000013505 freshwater Substances 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- -1 wooden boards Substances 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2002/001—Mechanical features of panels
- E04C2002/004—Panels with profiled edges, e.g. stepped, serrated
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2002/3488—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by frame like structures
Definitions
- the inventions herein relate to structures, such as dwellings and other buildings for residential occupancy, commercial occupancy and/or material storage, and to components for such structures.
- stick-built construction In the field of residential housing, the traditional technique for building homes is referred to as “stick-built” construction, where a builder constructs housing at the intended location using in substantial part raw materials such as wooden boards, plywood panels, and steel columns. The materials are assembled piece by piece over a previously prepared portion of ground, for example, a poured concrete slab or a poured concrete or cinder block foundation.
- Boxabl® foldable transportable dwelling unit which consists of a number of enclosure components (four wall components, a floor component and a roof component), and portions thereof, which are dimensioned, positioned and folded together to form a compact shipping module 15 , as shown in FIG. 1 A .
- the enclosure components and enclosure component portions are dimensioned so that the shipping module 15 is within applicable highway dimensional restrictions.
- shipping module 15 can be transported over a limited access highway more easily, and with appropriate trailering equipment, transported without the need for oversize load permits.
- structure 150 can be manufactured in a factory, positioned and joined together to form the shipping module 15 , and the modules 15 can then be transported to the desired site for the structure, where they can be readily deployed (unfolded) to yield a relatively finished structure 150 , which is shown in FIG. 1 B .
- factory manufacturing also has the potential to reduce manufacturing costs. For example, manufacturing improvements can advantageously reduce both assembly time and labor costs.
- manufacturing improvements can advantageously reduce both assembly time and labor costs.
- traditional home construction utilizes a great number of parts of different types. To capitalize on the efficiency of factory manufacturing, it is therefore desirable to reduce the variety of parts needed for dwelling assembly.
- the present invention constitutes an advancement in enclosure component design that reduces the number of core elements needed to manufacture the floor, roof and wall components of a dwelling unit.
- the present invention is directed to an enclosure component for a building structure, where the enclosure component comprises a first structural layer, a core layer and a second structural layer.
- the first structural layer has a first face, an opposed second face and comprises a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline arranged in a side-by-side relationship with a second structural panel of magnesium oxide.
- the core layer has a first face, an opposed second face and comprises a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, with a second edge of the foam spline opposed to the first edge of the foam spline arranged in a side-by-side relationship with a second foam panel, and with the first face of the core layer bonded to the second face of the first structural layer.
- a first lap joint spline of magnesium oxide is positioned between the first extension spline of the first structural layer and the first face of the core layer, and joins the first and second structural panels of the first structural layer.
- the second structural layer has a first face, an opposed second face and comprises a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, and with the second face of the core layer bonded to the first face of the second structural layer.
- a second lap joint spline of magnesium oxide is positioned between the second extension spline of the second structural layer and the second face of the core layer, and joins the first and second structural panels of the second structural layer.
- an exemplary enclosure component for a building structure has a length, a width and a thickness.
- the enclosure component includes a first structural layer having a first face, an opposed second face and including a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline in a side-by-side relationship with a second structural panel of magnesium oxide.
- the enclosure component includes a core layer having a first face, an opposed second face and including a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, and with a second edge of the foam spline opposed to the first edge of the foam spline in a side-by-side relationship with a second foam panel, with the first face of the core layer bonded to the second face of the first structural layer.
- the enclosure component includes a first lap joint spline of magnesium oxide, positioned between the first extension spline of the first structural layer and the first face of the core layer, and joining the first and second structural panels of the first structural layer.
- the enclosure component includes a second structural layer having a first face, an opposed second face and including a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, and with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, with the second face of the core layer bonded to the first face of the second structural layer.
- the enclosure component includes a second lap joint spline of magnesium oxide, positioned between the second extension spline of the second structural layer and the second face of the core layer, and joining the first and second structural panels of the second structural layer.
- the second extension spline can be proximate to the foam spline in a superposed relationship.
- the first extension spline can be distal from the foam spline.
- a surface of the first foam panel coinciding with the first face of the core layer can include a recess to receive the first extension spline.
- a portion of the first foam panel adjacent to the second face of the core layer and proximate to the first edge of the foam spline can define a recess to receive a first edge of the second lap joint spline
- a portion of the second foam panel adjacent to the second face of the core layer and proximate to the second edge of the foam spline can define a second recess to receive a second edge of the second lap joint spline opposed to the first edge of the second lap joint spline.
- the enclosure component can include a rigid beam within the foam spline, the rigid beam having a first surface that is coplanar with the second face of the core layer.
- the enclosure component can include a channel formed within the foam spline proximate to a second surface of the rigid beam. The channel is opposed to the first surface of the rigid beam and distal from the second face of the core layer.
- the foam spline can include a series of keys along the first edge of the foam spline and along the second edge of the foam spline.
- the first foam panel can include slots at first and second abutting edges.
- the second foam panel can include slots at first and second abutting edges.
- the series of keys along the first edge of the foam spline are configured to be received by the slots at the first abutting edge of the first foam panel, and the series of keys along the second edge of the foam spline are configured to be received by the slots at the second abutting edge of the second foam panel, to mate the first foam panel and the second foam panel to opposing sides of the foam spline.
- the foam spline can include a rigid beam disposed therein and extending a length of the foam spline.
- the foam spline can include a channel disposed adjacent to the rigid beam and extending the length of the foam spline.
- the first lap joint spline can be positioned under the first extension spline.
- the first lap joint spline can define a width dimensioned greater than a width of the first extension spline.
- the first lap joint spline can underlie the first extension spline and at least a portion of each of the first structural panel and the second structural panel.
- the first face of the core layer can include a recess formed therein, the recess dimensioned equally to a thickness of the first lap joint spline to receive the first lap joint spline such that the second face of the first structural layer lies flat against the first face of the core layer.
- the first structural layer is disposed against the first face of the core layer and the second structural layer is disposed against the second face of the core layer.
- a position of the first lap joint spline at the first face of the core layer is offset a distance along the core layer from a position of the second lap joint spline at the second face of the core layer. Seams of the first lap joint spline with the first structural layer do not match to corresponding seams of the second lap joint spline with the second structural layer across a thickness of the core layer due to the offset. Seams of the first structural layer do not match to corresponding seams of the second structural layer across a thickness of the core layer.
- FIG. 1 A is a perspective view of a folded building structure (a shipping module), and
- FIG. 1 B is a perspective view of an unfolded building structure.
- FIG. 2 is a top schematic view of the structure shown in FIG. 1 B .
- FIG. 3 is an end view of a shipping module as shown in FIG. 1 A , from which is formed the structure shown in FIG. 1 B .
- FIG. 4 is an exploded perspective view of the panel of the present invention.
- FIG. 5 is an exploded side view of the panel of the present invention.
- FIG. 6 is a side view of the panel of the present invention showing certain details of the foam spline and lap joint spline of the present invention.
- FIGS. 1 - 3 An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in FIGS. 1 - 3 .
- structure 150 When fully unfolded, as exemplified by FIG. 1 B , structure 150 has a rectangular shape made of three types of generally planar and rectangular enclosure components 155 , the three types of enclosure components 155 consisting of a wall component 200 , a floor component 300 , and a roof component 400 .
- the perimeter of structure 150 is defined by first longitudinal edge 106 , first transverse edge 108 , second longitudinal edge 116 and second transverse edge 110 .
- first longitudinal edge 106 and second longitudinal edge 116 may be referred to as the “longitudinal” direction
- a direction parallel to first transverse edge 108 and second transverse edge 110 may be referred to as the “transverse” direction
- a direction parallel to the vertical direction in FIG. 1 B may be referred to as the “vertical” direction.
- Structure 150 as shown has one floor component 300 , one roof component 400 and four wall components 200 ; although it should be understood that the present inventions are applicable to structures having other configurations as well.
- the enclosure components 155 of the present invention include a number of shared design features that are described below.
- Enclosure components 155 can be fabricated using a single universal panel 165 , which is characterized by a series of repeating elements to form an enclosure component 155 of an arbitrary size, as desired.
- the panel 165 utilizes a multi-layered, laminate design generally shown in FIG. 4 .
- the elements of panel 165 comprise a core layer 160 , a first structural layer 170 and a second structural layer 180 .
- a core unit 161 comprises a planar foam panel 163 adjoining a foam spline 164 , and each core unit 161 is the same as the other core units 161 ; i.e., core unit 161 1 , core unit 161 2 . . . core unit 161 m are the same.
- i ⁇ 2 m number of core units are arranged in a side-by-side, contacting relationship to form a core layer 160 of arbitrary length; i.e., foam panel 163 1 , foam spline 164 1 , foam panel 163 2 , foam spline 164 2 , . . . foam panel 164 m , foam spline 164 m .
- foam panel 163 1 foam panel 163 1
- foam spline 164 1 foam panel 163 2
- foam spline 164 2 foam spline 164 2
- . . . foam panel 164 m foam spline 164 m
- foam panels 163 can be facilitated by providing a series of keys 166 a along the edge of foam spline 164 , shown generally in FIG. 4 , which are received in corresponding slots 166 b located along the abutting edge of foam panel 163 .
- Foam panels 163 can be made for example of expanded polystyrene (EPS) or polyurethane foam.
- Each foam spline 164 has an elongate cuboid shape characterized by a foam spline length (“X” direction in FIG. 4 ) greater than the foam spline width (“Y” direction in FIG. 4 ) or the foam spline thickness (“Z” direction in FIG. 4 ), as shown in FIG. 4 .
- Foam splines 164 can be made of the same material as foam panels 163 , such as expanded polystyrene (EPS) or polyurethane foam.
- EPS expanded polystyrene
- a first surface of beam 167 whose area is defined by the length and width of beam 167 is coplanar with a first surface of foam spline 164 .
- a second surface of beam 167 which is opposed to the first surface of beam 167 and is distal from the first surface of foam spline 164 (referenced above), is proximate to a channel 169 , shown end-on in FIG. 6 .
- Channel 169 is formed in the interior of foam spline 164 and runs the length of foam spline 164 .
- Each beam 167 can be made for example of laminated veneer lumber.
- a first structural unit 171 comprises a planar first structural panel 211 adjacent a planar first extension spline 212 that is coplanar with the first structural panel 211 .
- m number of first structural units 171 are arranged in a side-by-side, contacting relationship (first structural panel 211 1 , first extension spline 212 1 , first structural panel 211 2 , first extension spline 212 2 , . . .
- first structural panel 211 m first extension spline 212 m
- first structural layer 170 first structural layer 170 of arbitrary length.
- i ⁇ 2 is a first structural unit 171 k positioned adjacent to a first structural unit 171 k+1
- first structural panel 211 k+1 of first structural unit 171 k+1 positioned adjacent to first extension spline 212 k of first structural unit 171 k
- An elongate planar first lap joint spline 213 in this case 213 k , is positioned under first extension spline 212 k .
- First lap joint spline 213 k has a width greater than the width of first extension spline 212 k so as to underlie a narrow portion of each of first structural panel 211 k+1 and first structural panel 211 k .
- a rectangular recess 168 k+ 1 is cut into foam panel 163 k+1 to receive first lap joint spline 213 k and allow the portions first structural panels 211 k , 211 k+1 overlapping foam panel 163 k+1 to lie flat against foam panel 163 k+1 , as shown in FIG. 6 .
- First structural panels 211 , first extension splines 212 and first lap joint splines 213 can each be made of an inorganic composition of relatively high strength, such as magnesium oxide (MgO).
- a second structural unit 181 comprises a planar second structural panel 216 adjacent a planar second extension spline 217 that is coplanar with the second structural panel 216 .
- m number of second structural units 181 are arranged in a side-by-side, contacting relationship (second structural panel 216 1 , second extension spline 217 1 , second structural panel 216 2 , second extension spline 217 2 , . . .
- second structural panel 216 m second extension spline 217 m
- second structural layer 180 of arbitrary length.
- i ⁇ 2 is a second structural unit 181 k positioned adjacent to a second structural unit 181 k+1
- second structural panel 216 k+1 of second structural unit 181 k+1 positioned adjacent to second extension spline 217 k of second structural unit 181 k
- 0 ⁇ k ⁇ m is a second structural unit 181 k positioned adjacent to a second structural unit 181 k+1
- second structural panel 216 k+1 of second structural unit 181 k+1 positioned adjacent to second extension spline 217 k of second structural unit 181 k
- each foam spline 164 is oriented so that the first surface of beam 167 , which is coplanar with the first surface of foam spline 164 , is adjacent to second structural layer 180 .
- an elongate planar second lap joint spline 218 is positioned under second extension spline 217 k .
- Second lap joint spline 218 k has a width greater than the width of second extension spline 217 k so as to overlap a narrow portion of each of second structural panel 216 k+1 and second structural panel 216 k .
- a rectangular recess edge 162 k is cut into the edge of foam panel 163 k to receive a first edge region of second lap joint spline 218 k
- a rectangular recess edge 162 k+1 is cut into the edge of foam panel 163 k+1 to receive a second edge region of second lap joint spline 218 k
- the thickness of foam spline 164 k is less than the thickness of foam panels 163 k , 163 k+1 by an amount equal to the thickness of second lap joint spline 218 k .
- Second structural panels 216 and second extension splines 217 can each be for example a cement board composition, and second lap joint splines 218 can each be made for example of magnesium oxide (MgO).
- the kth first extension spline 212 does not overlie the corresponding kth second extension spline 218 , but rather is offset a select distance so that the seams between and in each of the first structural units 171 do not match the corresponding seams between and in each of the second structural units 181 across the thickness (measured parallel to the z-axis) of panel 165 .
- the core layer 160 , first structural layer 170 and second structural layer 180 of each panel 165 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive.
- each first lap joint spline 213 underlying the narrow portion of the abutting first structural panel 211 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive
- the portion of each second lap joint spline 218 overlapping the narrow portion of the second structural panel 216 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive.
- each first structural panel 211 be four feet (1.22 m) wide by eight feet (2.44 m) long, and that each second structural panel 216 be four feet (1.22 m) wide by eight feet (2.44 m) long. It is further preferred that each first extension spline 212 be nine inches (0.23 m) wide by eight feet (2.44 m) long, and that each second extension spline 217 be nine inches (0.23 m) wide by eight feet (2.44 m) long. With these dimensions, each first structural unit 171 , core unit 161 and second structural unit 181 will have a width of 57 inches (1.45 m).
- each enclosure component 155 i.e., the edges that define the perimeter of enclosure component 155
- Exterior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the exterior edges of enclosure components 155 .
- Exterior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the exterior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.
- Enclosure components 155 in certain instances are partitioned into enclosure component portions to facilitate forming a compact shipping module 15 .
- any exterior edge reinforcement on the exterior edges defining the perimeter of the enclosure component is segmented as necessary between or among the portions.
- the enclosure component portions can be joined by hinge structures or mechanisms to permit the enclosure component portions to be “folded” and thereby contribute to forming a compact shipping module 15 .
- An enclosure component 155 partitioned into enclosure component portions will have interior edges. There will be two adjacent interior edges for each adjacent pair of enclosure component portions. Such interior edges can be provided with interior edge reinforcement. Similar to exterior edge reinforcement, such interior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the interior edges of enclosure components 155 . Interior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the interior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.
- wall component 200 floor component 300 , and roof component 400 are provided in the sections following.
- structure 150 will utilize four wall components 200 , with each wall component 200 corresponding to an entire wall of structure 150 .
- Wall component 200 has a generally rectangular perimeter. As shown in FIG. 1 B , wall components 200 have plural apertures, specifically a door aperture 202 , which has a door frame and door assembly, and plural window apertures 204 , each of which has a window frame and a window assembly.
- the height and length of wall components 200 can vary in accordance with design preference, subject as desired to the dimensional restrictions applicable to transport, described above.
- structure 150 is fashioned with all sides of equal length; accordingly, its first and second longitudinal edges 106 and 116 , and its first and second transverse edges 108 and 110 , are all of equal length. It should be understood however, that the inventions described herein are applicable to structures having other dimensions, such as where two opposing wall components 200 are longer than the other two opposing wall components 200 .
- structure 150 has two opposing wall components 200 , where one of the two opposing wall components 200 comprises first wall portion 200 s - 1 and second wall portion 200 s - 2 , and the other of the two opposing wall components 200 comprises third wall portion 200 s - 3 and fourth wall portion 200 s - 4 .
- Each of wall portions 200 s - 1 , 200 s - 2 , 200 s - 3 and 200 s - 4 has a generally rectangular planar structure. As shown in FIG.
- the interior vertical edge 192 - 1 of wall portion 200 s - 1 is proximate to a respective interior vertical edge 192 - 2 of wall portion 200 s - 2
- the interior vertical edge 194 - 3 of wall portion 200 s - 3 is proximate a respective interior vertical wall edge 194 - 4 of wall portion 200 s - 4 .
- first wall portion 200 s - 1 is fixed in position on floor portion 300 a proximate to first transverse edge 108
- third wall portion 200 s - 3 is fixed in position on floor portion 300 a , opposite first wall portion 200 s - 1 and proximate to second transverse edge 110 .
- First wall portion 200 s - 1 is joined to second wall portion 200 s - 2 with a hinge structure that permits wall portion 200 s - 2 to pivot about vertical axis 192 between a folded position and an unfolded position
- third wall portion 200 s - 3 is joined to fourth wall portion 200 s - 4 with a hinge structure to permit fourth wall portion 200 s - 4 to pivot about vertical axis 194 between a folded position and an unfolded position.
- first wall portion 200 s - 1 is longer than third wall portion 200 s - 3 by a distance approximately equal to the thickness of wall component 200
- second wall portion 200 s - 2 is shorter than fourth wall portion 200 s - 4 by a distance approximately equal to the thickness of wall component 200
- wall portion 200 s - 1 and wall portion 200 s - 3 are each shorter in length (the dimension in the transverse direction) than the dimension of floor portion 300 a in the transverse direction.
- FIG. 2 depicts wall portions 200 s - 2 and 200 s - 4 both in their unfolded positions, where they are labelled 200 s - 2 u and 200 s 4 - u respectively, and FIG. 2 also depicts wall portions 200 s - 2 and 200 s - 4 both in their inwardly folded positions, where they are labelled 200 s - 2 f and 200 s 4 - f respectively.
- wall portions 200 s - 2 and 200 s - 4 When wall portions 200 s - 2 and 200 s - 4 are in their inwardly folded positions ( 200 s - 2 f and 200 s - 4 f ), they facilitate forming a compact shipping module.
- wall portion 200 s - 2 When wall portion 200 s - 2 is in its unfolded position ( 200 s - 2 u ), it forms with wall portion 200 s - 1 a wall component 200 proximate first transverse edge 108 , and when wall portion 200 s - 4 is in its unfolded position ( 200 s - 4 u ), it forms with wall portion 200 s - 3 a wall component 200 proximate second transverse edge 110 .
- the remaining two wall components 200 proximate first and second longitudinal edges 106 and 116 do not comprise plural wall portions, but rather each is a single piece structure.
- one of these wall components 200 which is sometimes denominated 200 P in this disclosure, and which is located on floor portion 300 b proximate first longitudinal edge 106 , is pivotally secured to floor portion 300 b to permit wall component 200 P to pivot about horizontal axis 105 shown in FIG. 3 from a folded position to an unfolded position. Pivotally securing wall component 200 P also facilitates forming a compact shipping module 15 .
- the remaining wall component 200 is rigidly secured on floor portion 300 a proximate second longitudinal edge 116 and abutting the vertical edges of first wall portion 200 s - 1 and third wall portion 200 s - 3 proximate to second longitudinal edge 116 , as shown in FIG. 2 .
- structure 150 will utilize one floor component 300 ; thus floor component 300 generally is the full floor of structure 150 .
- Floor component 300 has a generally rectangular perimeter. The length and width of floor component 300 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIGS. 1 B and 2 , floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).
- Floor component 300 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which floor component 300 may be subject.
- the floor component 300 is partitioned into floor portion 300 a and floor portion 300 b .
- FIG. 2 shows flow portions 300 a and 300 b in plan view.
- Each of the floor portions 300 a and 300 b is a planar generally rectangular structure, with floor portion 300 a adjoining floor portion 300 b.
- floor portion 300 a is fixed in position relative to first wall portion 200 s - 1 , third wall portion 200 s - 3 and wall component 200 R.
- Floor portion 300 a is joined with hinge structures to floor portion 300 b , so as to permit floor portion 300 b to pivot through approximately ninety degrees (90°) of arc about a horizontal axis 305 , generally located as indicated in FIG. 3 , proximate the top surface of floor component 300 , between a fully folded position, where floor portion 300 b is vertically oriented as shown in FIG. 3 , and the fully unfolded position shown in FIG. 2 , where floor portion 300 b is horizontally oriented and co-planar with floor portion 300 a.
- 90° ninety degrees
- structure 150 will utilize one roof component 400 ; thus roof component 400 generally is the full roof of structure 150 .
- Roof component 400 has a generally rectangular perimeter.
- FIG. 1 B depicts roof component 400 .
- the length and width of roof component 400 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIG. 1 B , the length and width of roof component 400 approximates the length and width of floor component 300 .
- Roof component 400 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which roof component 400 may be subject.
- the roof component 400 of structure 150 is partitioned into roof portions 400 a , 400 b and 400 c , shown in FIGS. 1 A and 3 when folded, and in FIG. 1 B when unfolded.
- Each of the roof portions 400 a , 400 b and 400 c is a planar generally rectangular structure, with roof portion 400 a adjoining roof portion 400 b , and roof portion 400 b adjoining roof portion 400 c.
- roof portions 400 a , 400 b and 400 c preferably are accordion folded (stacked), with roof component 400 b stacked on top of roof component 400 a , and roof component 400 c stacked on top of the roof component 400 b .
- roof portion 400 a is fixed in position relative to first wall portion 200 s - 1 , third wall portion 200 s - 3 and wall component 200 R.
- roof portion 400 a is joined to roof portion 400 b with hinge structures that are adapted to permit roof portion 400 b to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405 a (see FIG. 3 ) between the roof fully folded position shown in FIGS. 1 A and 3 , where roof portion 400 b lies stacked flat against roof portion 400 a , and the fully unfolded position shown in FIG. 1 B .
- roof portion 400 b is joined to roof portion 400 c with hinge structures that are adapted to permit roof portion 400 c to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405 b (see FIG. 3 ) between the folded position shown in FIGS. 1 A and 3 , where roof portion 400 c lies stacked flat against roof portion 400 b (when roof portion 400 b is positioned to lie flat against roof portion 400 a ), and the fully unfolded position shown in FIG. 1 B .
- structure 150 includes a fixed space portion 102 defined by roof component 400 a (shown in FIG. 3 ), floor component 300 a , wall component 200 R, wall portion 200 s - 1 and wall portion 200 s - 3 .
- (Fixed space portion 102 is also shown edge-on in the shipping module 15 depicted in FIG. 3 ). It is preferred that the fixed space portion 102 be fitted out during manufacture with internal components, such as kitchens, bathrooms, closets, storage areas, corridors, etc., so as to be in a relatively finished state prior to shipment of shipping module 15 .
- wall components 200 are fitted during manufacture and prior to shipment with all necessary door and window assemblies, with the enclosure components 155 being pre-wired for electrical needs.
- Carrying out the foregoing steps prior to shipment permits the builder, in effect, to erect a largely finished structure simply by “unfolding” (deploying) the positioned components of shipping module 15 .
- enclosure components 155 It is preferred that there be a specific dimensional relationship among enclosure components 155 .
- FIG. 2 shows a top schematic view of structure 150 shown in FIGS. 1 A and 1 B , and includes a geometrical orthogonal grid for clarity of explaining the preferred dimensional relationships among its enclosure components 155 .
- the basic length used for dimensioning is indicated as “E” in FIG. 2 ; the orthogonal grid overlaid in FIG. 2 is 4E long and 4E wide; notably, the entire structure 150 preferably is bounded by this 4E by 4E orthogonal grid.
- Roof portions 400 a , 400 b and 400 c each can be identically dimensioned in the transverse direction.
- roof portion 400 c can be dimensioned to be larger than either of roof portion 400 a and roof portion 400 b in the transverse direction to reduce the chances of binding during the unfolding of roof portions 400 b , 400 c .
- Further specifics on dimensioning roof portion 400 c in the foregoing manner are described in U.S. Non-Provisional application Ser. No. 17/569,962, entitled “Improved Folding Roof Component,” filed on Jan. 6, 2022.
- friction-reducing components can be used to facilitate unfolding roof component 400 , such as by positioning a first wheel caster at the leading edge of roof portion 400 c proximate to the corner of roof portion 400 c that is supported by wall portion 200 s - 2 as roof portion 400 c is deployed, and by positioning a second similar wheel caster at the leading edge of roof portion 400 c proximate to the corner of roof portion 400 c that is supported by wall portion 200 s - 4 as roof portion 400 c is deployed.
- the four wall components 200 are each approximately 4E long, and each of roof portions 400 a and 400 b is approximately 4E long and 1.25E wide. Roof portion 400 c is approximately 4E long and 1.45E wide.
- each of floor components 300 a and 300 b is 4E long; whereas floor component 300 a is just over 1.5E wide and floor component 300 b is just under 2.5E wide.
- fourth wall portion 200 s - 4 is folded inward and positioned generally against fixed space portion 102
- second wall portion 200 s - 2 is folded inward and positioned generally against fourth wall portion 200 s - 4
- wall portions 200 s - 2 and 200 s - 4 are respectively identified in FIG. 2 as portions 200 s - 2 f and 200 s - 4 f when so folded and positioned.
- the three roof components 400 a , 400 b and 400 c are shown unfolded in FIG. 1 B and shown folded (stacked) in FIG. 3 , with roof component 400 b stacked on top of roof component 400 a , and roof component 400 c stacked on top of the roof component 400 b .
- Wall component 200 P shown in FIGS. 2 and 3 , is pivotally secured to floor portion 300 b at the location of axis 105 , and is vertically positioned against the outside of wall portions 200 s - 2 and 200 s - 4 .
- floor portion 300 b is vertically positioned proximate fixed space portion 102 , with wall component 200 P pending from floor portion 300 b between floor portion 300 b and wall portions 200 s - 2 and 200 s - 4 .
- shipping module 15 depicted in FIG. 3 when dimensioned according to the relationships disclosed herein using an “E” dimension (see FIG. 2 ) of 57 inches (144.8 cm), and when its components are stacked and positioned as shown in FIG. 3 , has an overall length of approximately 19 feet (5.79 m), an overall width of approximately 8.5 feet (2.59 meters) and an overall height of approximately 12.7 feet (3.87 meters). These overall dimensions are less than a typical shipping container.
- Each of the wall, floor and roof components 200 , 300 and 400 , and/or the portions thereof, can be sheathed in protective film during fabrication and prior to forming the shipping module 15 .
- the entire shipping module 15 can be sheathed in a protective film.
- Such protective films can remain in place until after the shipping module 15 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.
- the shipping module 15 is shipped to the building site by appropriate transport means.
- One such transport means is disclosed in U.S. Non-Provisional application Ser. No. 16/143,628, filed Sep. 27, 2018 and now U.S. Pat. No. 11,007,921, issued May 18, 2021; the contents of that U.S. Non-Provisional application Ser. No. 16/143,628, filed Sep. 27, 2018, are incorporated by reference as if fully set forth herein, particularly as found at paragraphs 0020-0035 and in FIGS. 1 A- 2 D thereof.
- shipping module 15 can be shipped to the building site by means of a conventional truck trailer or a low bed trailer (also referred to as a lowboy trailer), and in the case of over-the-water shipments, by ship.
- shipping module 15 is positioned over its desired location, such as over a prepared foundation; for example, a poured concrete slab, a poured concrete or cinder block foundation, sleeper beams or concrete posts or columns.
- a prepared foundation for example, a poured concrete slab, a poured concrete or cinder block foundation, sleeper beams or concrete posts or columns.
- This can be accomplished by using a crane, either to lift shipping module 15 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 15 , then moving the transport means from the desired location, and then lowering shipping module 15 to a rest state at the desired location.
- a crane either to lift shipping module 15 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 15 , then moving the transport means from the desired location, and then lowering shipping module 15 to a rest state at the desired location.
- Particularly suitable equipment and techniques for facilitating the positioning of a shipping module 15 at the desired location are disclosed in
- unfolding occurs in the following sequence: (1) floor portion 300 b is pivotally rotated about horizontal axis 305 (shown in FIG. 3 ) to an unfolded position, (2) wall component 200 P is pivotally rotated about horizontal axis 105 (the general location of which is shown in FIG. 3 ) to an unfolded position, (3) wall portions 200 s - 2 and 200 s - 4 are pivotally rotated about vertical axes 192 and 194 (shown in FIG. 2 ) respectively to unfolded positions, and (4) roof portions 400 b and 400 c are pivotally rotated about horizontal axes 405 a and 405 b (shown in FIG. 3 ) respectively to unfolded positions.
- the enclosure components 155 are secured together to finish the structure 150 that is shown in FIG. 1 A .
- any remaining finishing operations are performed, such as addition of roofing material, and making hook-ups to electrical, fresh water and sewer lines to complete structure 150 , as relevant here.
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Abstract
An enclosure component for a building structure is provided and includes a first structural panel arranged in a side-by-side relationship with a first edge of a first extension spline, and with a second edge of the first extension spline opposed to the first edge of the first extension spline in a side-by-side relationship with a second structural panel. The component includes a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, and with a second edge of the foam spline opposed to the first edge of the foam spline in a side-by-side relationship with a second foam panel. The component includes a first structural panel arranged in a side-by-side relationship with a first edge of a second extension spline, and with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel.
Description
- This application claims the benefit of U.S. Provisional Patent Application No. 63/388,366, which was filed on Jul. 12, 2022. The entire content of the foregoing provisional application is incorporated herein by reference.
- The inventions herein relate to structures, such as dwellings and other buildings for residential occupancy, commercial occupancy and/or material storage, and to components for such structures.
- In the field of residential housing, the traditional technique for building homes is referred to as “stick-built” construction, where a builder constructs housing at the intended location using in substantial part raw materials such as wooden boards, plywood panels, and steel columns. The materials are assembled piece by piece over a previously prepared portion of ground, for example, a poured concrete slab or a poured concrete or cinder block foundation.
- There have been a variety of efforts to depart from the conventional construction techniques used to create dwellings, as well as commercial spaces and like, in an effort to reduce costs. In this regard, a significant advancement is embodied in the Boxabl® foldable transportable dwelling unit, which consists of a number of enclosure components (four wall components, a floor component and a roof component), and portions thereof, which are dimensioned, positioned and folded together to form a
compact shipping module 15, as shown inFIG. 1A . The enclosure components and enclosure component portions are dimensioned so that theshipping module 15 is within applicable highway dimensional restrictions. As a result,shipping module 15 can be transported over a limited access highway more easily, and with appropriate trailering equipment, transported without the need for oversize load permits. Thus, the basic components ofstructure 150 can be manufactured in a factory, positioned and joined together to form theshipping module 15, and themodules 15 can then be transported to the desired site for the structure, where they can be readily deployed (unfolded) to yield a relatively finishedstructure 150, which is shown inFIG. 1B . - The use of factory manufacturing also has the potential to reduce manufacturing costs. For example, manufacturing improvements can advantageously reduce both assembly time and labor costs. Relatedly, traditional home construction utilizes a great number of parts of different types. To capitalize on the efficiency of factory manufacturing, it is therefore desirable to reduce the variety of parts needed for dwelling assembly.
- The present invention constitutes an advancement in enclosure component design that reduces the number of core elements needed to manufacture the floor, roof and wall components of a dwelling unit.
- In one aspect, the present invention is directed to an enclosure component for a building structure, where the enclosure component comprises a first structural layer, a core layer and a second structural layer. The first structural layer has a first face, an opposed second face and comprises a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline arranged in a side-by-side relationship with a second structural panel of magnesium oxide. The core layer has a first face, an opposed second face and comprises a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, with a second edge of the foam spline opposed to the first edge of the foam spline arranged in a side-by-side relationship with a second foam panel, and with the first face of the core layer bonded to the second face of the first structural layer. A first lap joint spline of magnesium oxide is positioned between the first extension spline of the first structural layer and the first face of the core layer, and joins the first and second structural panels of the first structural layer. The second structural layer has a first face, an opposed second face and comprises a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, and with the second face of the core layer bonded to the first face of the second structural layer. A second lap joint spline of magnesium oxide is positioned between the second extension spline of the second structural layer and the second face of the core layer, and joins the first and second structural panels of the second structural layer.
- In accordance with embodiments of the present disclosure, an exemplary enclosure component for a building structure is provided. The enclosure component has a length, a width and a thickness. The enclosure component includes a first structural layer having a first face, an opposed second face and including a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline in a side-by-side relationship with a second structural panel of magnesium oxide. The enclosure component includes a core layer having a first face, an opposed second face and including a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, and with a second edge of the foam spline opposed to the first edge of the foam spline in a side-by-side relationship with a second foam panel, with the first face of the core layer bonded to the second face of the first structural layer. The enclosure component includes a first lap joint spline of magnesium oxide, positioned between the first extension spline of the first structural layer and the first face of the core layer, and joining the first and second structural panels of the first structural layer. The enclosure component includes a second structural layer having a first face, an opposed second face and including a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, and with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, with the second face of the core layer bonded to the first face of the second structural layer. The enclosure component includes a second lap joint spline of magnesium oxide, positioned between the second extension spline of the second structural layer and the second face of the core layer, and joining the first and second structural panels of the second structural layer.
- The second extension spline can be proximate to the foam spline in a superposed relationship. The first extension spline can be distal from the foam spline. A surface of the first foam panel coinciding with the first face of the core layer can include a recess to receive the first extension spline. A portion of the first foam panel adjacent to the second face of the core layer and proximate to the first edge of the foam spline can define a recess to receive a first edge of the second lap joint spline, and a portion of the second foam panel adjacent to the second face of the core layer and proximate to the second edge of the foam spline can define a second recess to receive a second edge of the second lap joint spline opposed to the first edge of the second lap joint spline.
- The enclosure component can include a rigid beam within the foam spline, the rigid beam having a first surface that is coplanar with the second face of the core layer. The enclosure component can include a channel formed within the foam spline proximate to a second surface of the rigid beam. The channel is opposed to the first surface of the rigid beam and distal from the second face of the core layer.
- The foam spline can include a series of keys along the first edge of the foam spline and along the second edge of the foam spline. The first foam panel can include slots at first and second abutting edges. The second foam panel can include slots at first and second abutting edges. The series of keys along the first edge of the foam spline are configured to be received by the slots at the first abutting edge of the first foam panel, and the series of keys along the second edge of the foam spline are configured to be received by the slots at the second abutting edge of the second foam panel, to mate the first foam panel and the second foam panel to opposing sides of the foam spline.
- The foam spline can include a rigid beam disposed therein and extending a length of the foam spline. The foam spline can include a channel disposed adjacent to the rigid beam and extending the length of the foam spline.
- The first lap joint spline can be positioned under the first extension spline. The first lap joint spline can define a width dimensioned greater than a width of the first extension spline. The first lap joint spline can underlie the first extension spline and at least a portion of each of the first structural panel and the second structural panel. The first face of the core layer can include a recess formed therein, the recess dimensioned equally to a thickness of the first lap joint spline to receive the first lap joint spline such that the second face of the first structural layer lies flat against the first face of the core layer.
- The first structural layer is disposed against the first face of the core layer and the second structural layer is disposed against the second face of the core layer. A position of the first lap joint spline at the first face of the core layer is offset a distance along the core layer from a position of the second lap joint spline at the second face of the core layer. Seams of the first lap joint spline with the first structural layer do not match to corresponding seams of the second lap joint spline with the second structural layer across a thickness of the core layer due to the offset. Seams of the first structural layer do not match to corresponding seams of the second structural layer across a thickness of the core layer.
- These and other aspects of the present inventions are described in the drawings annexed hereto, and in the description of the preferred embodiments and claims set forth below.
-
FIG. 1A is a perspective view of a folded building structure (a shipping module), and -
FIG. 1B is a perspective view of an unfolded building structure. -
FIG. 2 is a top schematic view of the structure shown inFIG. 1B . -
FIG. 3 is an end view of a shipping module as shown inFIG. 1A , from which is formed the structure shown inFIG. 1B . -
FIG. 4 is an exploded perspective view of the panel of the present invention. -
FIG. 5 is an exploded side view of the panel of the present invention. -
FIG. 6 is a side view of the panel of the present invention showing certain details of the foam spline and lap joint spline of the present invention. - An embodiment of the foldable,
transportable structure 150 in which the inventions disclosed herein can be implemented is depicted inFIGS. 1-3 . When fully unfolded, as exemplified byFIG. 1B ,structure 150 has a rectangular shape made of three types of generally planar andrectangular enclosure components 155, the three types ofenclosure components 155 consisting of awall component 200, afloor component 300, and aroof component 400. As shown inFIGS. 1A, 1B and 2 , the perimeter ofstructure 150 is defined by firstlongitudinal edge 106, firsttransverse edge 108, secondlongitudinal edge 116 and secondtransverse edge 110. For convenience, a direction parallel to firstlongitudinal edge 106 and secondlongitudinal edge 116 may be referred to as the “longitudinal” direction, a direction parallel to firsttransverse edge 108 and secondtransverse edge 110 may be referred to as the “transverse” direction; and a direction parallel to the vertical direction inFIG. 1B may be referred to as the “vertical” direction.Structure 150 as shown has onefloor component 300, oneroof component 400 and fourwall components 200; although it should be understood that the present inventions are applicable to structures having other configurations as well. - The
enclosure components 155 of the present invention include a number of shared design features that are described below. - A. Laminate Structure Design
-
Enclosure components 155 can be fabricated using a singleuniversal panel 165, which is characterized by a series of repeating elements to form anenclosure component 155 of an arbitrary size, as desired. - The
panel 165 utilizes a multi-layered, laminate design generally shown inFIG. 4 . The elements ofpanel 165 comprise acore layer 160, a firststructural layer 170 and a secondstructural layer 180. - As shown in
FIGS. 4 and 5 ,core layer 160 comprises one or a series of repeating core units 161 i, i in number, where i=1, 2, . . . m. A core unit 161 comprises aplanar foam panel 163 adjoining afoam spline 164, and each core unit 161 is the same as the other core units 161; i.e., core unit 161 1, core unit 161 2 . . . core unit 161 m are the same. In the case where i≥2, m number of core units are arranged in a side-by-side, contacting relationship to form acore layer 160 of arbitrary length; i.e.,foam panel 163 1,foam spline 164 1,foam panel 163 2,foam spline 164 2, . . .foam panel 164 m,foam spline 164 m. Thus the general relationship where i≥2 is a core unit 161 k positioned adjacent to a core unit 161 k+1, where 0<k≤m. The mating offoam panels 163 withfoam splines 164 can be facilitated by providing a series ofkeys 166 a along the edge offoam spline 164, shown generally inFIG. 4 , which are received in correspondingslots 166 b located along the abutting edge offoam panel 163.Foam panels 163 can be made for example of expanded polystyrene (EPS) or polyurethane foam. - Each
foam spline 164 has an elongate cuboid shape characterized by a foam spline length (“X” direction inFIG. 4 ) greater than the foam spline width (“Y” direction inFIG. 4 ) or the foam spline thickness (“Z” direction inFIG. 4 ), as shown inFIG. 4 . Foam splines 164 can be made of the same material asfoam panels 163, such as expanded polystyrene (EPS) or polyurethane foam. There is provided within each foam spline 164 arigid beam 167, shown end-on inFIG. 6 , which has an elongate cuboid shape of six surfaces characterized by a beam length (the dimension in the “X” direction, into/out of the drawing shown inFIG. 6 ) greater than the beam width or the beam thickness, and in the embodiment shown the beam width is greater than the beam thickness. A first surface ofbeam 167 whose area is defined by the length and width ofbeam 167 is coplanar with a first surface offoam spline 164. A second surface ofbeam 167, which is opposed to the first surface ofbeam 167 and is distal from the first surface of foam spline 164 (referenced above), is proximate to achannel 169, shown end-on inFIG. 6 .Channel 169 is formed in the interior offoam spline 164 and runs the length offoam spline 164. Eachbeam 167 can be made for example of laminated veneer lumber. - Referring particularly to
FIG. 5 , the firststructural layer 170 comprises first structural units 1711, i in number, where i=1, 2, . . . m. A firststructural unit 171 comprises a planar firststructural panel 211 adjacent a planarfirst extension spline 212 that is coplanar with the firststructural panel 211. In the case where i≥2, m number of firststructural units 171 are arranged in a side-by-side, contacting relationship (firststructural panel 211 1,first extension spline 212 1, firststructural panel 211 2,first extension spline 212 2, . . . firststructural panel 211 m, first extension spline 212 m) to form a firststructural layer 170 of arbitrary length. Thus, the general relationship where i≥2 is a firststructural unit 171 k positioned adjacent to a firststructural unit 171 k+1, with firststructural panel 211 k+1 of firststructural unit 171 k+1 positioned adjacent tofirst extension spline 212 k of firststructural unit 171 k, where 0<k≤m. An elongate planar first lapjoint spline 213, in thiscase 213 k, is positioned underfirst extension spline 212 k. First lapjoint spline 213 k has a width greater than the width offirst extension spline 212 k so as to underlie a narrow portion of each of firststructural panel 211 k+1 and firststructural panel 211 k. A rectangular recess 168 k+1 is cut intofoam panel 163 k+1 to receive first lapjoint spline 213 k and allow the portions firststructural panels foam panel 163 k+1 to lie flat againstfoam panel 163 k+1, as shown inFIG. 6 . Firststructural panels 211, first extension splines 212 and first lapjoint splines 213 can each be made of an inorganic composition of relatively high strength, such as magnesium oxide (MgO). - Continuing to particularly refer to
FIG. 5 , the secondstructural layer 180 comprises second structural units 181 i, i in number, where i=1, 2, . . . m. A second structural unit 181 comprises a planar secondstructural panel 216 adjacent a planarsecond extension spline 217 that is coplanar with the secondstructural panel 216. In the case where i≥2, m number of second structural units 181 are arranged in a side-by-side, contacting relationship (secondstructural panel 216 1,second extension spline 217 1, secondstructural panel 216 2,second extension spline 217 2, . . . secondstructural panel 216 m, second extension spline 217 m) to form a secondstructural layer 180 of arbitrary length. Thus, the general relationship where i≥2 is a second structural unit 181 k positioned adjacent to a second structural unit 181 k+1, with secondstructural panel 216 k+1 of second structural unit 181 k+1 positioned adjacent tosecond extension spline 217 k of second structural unit 181 k, where 0<k≤m. - As can be seen in
FIG. 6 , eachfoam spline 164 is oriented so that the first surface ofbeam 167, which is coplanar with the first surface offoam spline 164, is adjacent to secondstructural layer 180. - As shown in
FIG. 5 , an elongate planar second lapjoint spline 218, in thiscase 218 k, is positioned undersecond extension spline 217 k. Second lapjoint spline 218 k has a width greater than the width ofsecond extension spline 217 k so as to overlap a narrow portion of each of secondstructural panel 216 k+1 and secondstructural panel 216 k. A rectangular recess edge 162 k is cut into the edge offoam panel 163 k to receive a first edge region of second lapjoint spline 218 k, a rectangular recess edge 162 k+1 is cut into the edge offoam panel 163 k+1 to receive a second edge region of second lapjoint spline 218 k and the thickness offoam spline 164 k is less than the thickness offoam panels joint spline 218 k. to allow the portions of secondstructural panels foam panels foam panels FIG. 6 . Secondstructural panels 216 and second extension splines 217 can each be for example a cement board composition, and second lapjoint splines 218 can each be made for example of magnesium oxide (MgO). - As is evident from the foregoing, and as can be seen in for example
FIGS. 5 and 6 , the kthfirst extension spline 212 does not overlie the corresponding kthsecond extension spline 218, but rather is offset a select distance so that the seams between and in each of the firststructural units 171 do not match the corresponding seams between and in each of the second structural units 181 across the thickness (measured parallel to the z-axis) ofpanel 165. Thecore layer 160, firststructural layer 170 and secondstructural layer 180 of eachpanel 165 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive. Likewise, the portion of each first lapjoint spline 213 underlying the narrow portion of the abutting firststructural panel 211 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive, and the portion of each second lapjoint spline 218 overlapping the narrow portion of the secondstructural panel 216 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive. - It is preferred that each first
structural panel 211 be four feet (1.22 m) wide by eight feet (2.44 m) long, and that each secondstructural panel 216 be four feet (1.22 m) wide by eight feet (2.44 m) long. It is further preferred that eachfirst extension spline 212 be nine inches (0.23 m) wide by eight feet (2.44 m) long, and that eachsecond extension spline 217 be nine inches (0.23 m) wide by eight feet (2.44 m) long. With these dimensions, each firststructural unit 171, core unit 161 and second structural unit 181 will have a width of 57 inches (1.45 m). - Another embodiment of a laminate design that can be used to fabricate
enclosure components 155 is described in U.S. Non-Provisional patent application Ser. No. 17/552,108, entitled “Enclosure Component Fabrication Facility,” filed on Dec. 15, 2021. The contents of that U.S. Non-Provisional patent application Ser. No. 17/552,108, entitled “Enclosure Component Fabrication Facility,” filed on Dec. 15, 2021 are incorporated by reference as if fully set forth herein, particularly including the multi-layered, laminate designs described for example at ¶¶0027-0032 and depicted inFIG. 7 . - Yet other embodiments of multi-layered, laminate designs that can be used to fabricate the
enclosure components 155 of the present invention, are described in U.S. Non-Provisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures,” filed on Feb. 10, 2020 and now issued as U.S. Pat. No. 11,118,344. The contents of that U.S. Non-Provisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures” and filed on Feb. 10, 2020 are incorporated by reference as if fully set forth herein, particularly including the multi-layered, laminate designs described for example at ¶¶0034-57 and depicted inFIGS. 4A-4D thereof. - B. Enclosure Component Exterior Edge Reinforcement
- The exterior edges of each enclosure component 155 (i.e., the edges that define the perimeter of enclosure component 155) can be provided with exterior edge reinforcement, as desired. Exterior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the exterior edges of
enclosure components 155. Exterior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the exterior edges ofenclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive. - C. Enclosure Component Partitioning
-
Enclosure components 155 in certain instances are partitioned into enclosure component portions to facilitate forming acompact shipping module 15. In those instances where anenclosure component 155 is partitioned into enclosure component portions, any exterior edge reinforcement on the exterior edges defining the perimeter of the enclosure component is segmented as necessary between or among the portions. - The enclosure component portions can be joined by hinge structures or mechanisms to permit the enclosure component portions to be “folded” and thereby contribute to forming a
compact shipping module 15. - D. Enclosure Component Interior Edge Reinforcement
- An
enclosure component 155 partitioned into enclosure component portions will have interior edges. There will be two adjacent interior edges for each adjacent pair of enclosure component portions. Such interior edges can be provided with interior edge reinforcement. Similar to exterior edge reinforcement, such interior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the interior edges ofenclosure components 155. Interior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the interior edges ofenclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive. - Further design details of
wall component 200,floor component 300, androof component 400 are provided in the sections following. - Typically,
structure 150 will utilize fourwall components 200, with eachwall component 200 corresponding to an entire wall ofstructure 150. - A. General Description
-
Wall component 200 has a generally rectangular perimeter. As shown inFIG. 1B ,wall components 200 have plural apertures, specifically adoor aperture 202, which has a door frame and door assembly, andplural window apertures 204, each of which has a window frame and a window assembly. The height and length ofwall components 200 can vary in accordance with design preference, subject as desired to the dimensional restrictions applicable to transport, described above. In this disclosure,structure 150 is fashioned with all sides of equal length; accordingly, its first and secondlongitudinal edges transverse edges wall components 200 are longer than the other two opposingwall components 200. - B. Partitioned Wall Components
- Referring to
FIG. 2 ,structure 150 has two opposingwall components 200, where one of the two opposingwall components 200 comprisesfirst wall portion 200 s-1 andsecond wall portion 200 s-2, and the other of the two opposingwall components 200 comprisesthird wall portion 200 s-3 andfourth wall portion 200 s-4. Each ofwall portions 200 s-1, 200 s-2, 200 s-3 and 200 s-4 has a generally rectangular planar structure. As shown inFIG. 2 , the interior vertical edge 192-1 ofwall portion 200 s-1 is proximate to a respective interior vertical edge 192-2 ofwall portion 200 s-2, and the interior vertical edge 194-3 ofwall portion 200 s-3 is proximate a respective interior vertical wall edge 194-4 ofwall portion 200 s-4. - Referring again to
FIG. 2 ,first wall portion 200 s-1 is fixed in position onfloor portion 300 a proximate to firsttransverse edge 108, andthird wall portion 200 s-3 is fixed in position onfloor portion 300 a, oppositefirst wall portion 200 s-1 and proximate to secondtransverse edge 110.First wall portion 200 s-1 is joined tosecond wall portion 200 s-2 with a hinge structure that permitswall portion 200 s-2 to pivot aboutvertical axis 192 between a folded position and an unfolded position, andthird wall portion 200 s-3 is joined tofourth wall portion 200 s-4 with a hinge structure to permitfourth wall portion 200 s-4 to pivot aboutvertical axis 194 between a folded position and an unfolded position. - Notably,
first wall portion 200 s-1 is longer thanthird wall portion 200 s-3 by a distance approximately equal to the thickness ofwall component 200, andsecond wall portion 200 s-2 is shorter thanfourth wall portion 200 s-4 by a distance approximately equal to the thickness ofwall component 200. Furthermore,wall portion 200 s-1 andwall portion 200 s-3 are each shorter in length (the dimension in the transverse direction) than the dimension offloor portion 300 a in the transverse direction. Dimensioning the lengths ofwall portions 200 s-1, 200 s-2, 200 s-3 and 200 s-4 in this manner permitswall portions 200 s-2 and 200 s-4 to nest against each other in an overlapping relationship when in an inwardly folded position. In this regard,FIG. 2 depictswall portions 200 s-2 and 200 s-4 both in their unfolded positions, where they are labelled 200 s-2 u and 200 s 4-u respectively, andFIG. 2 also depictswall portions 200 s-2 and 200 s-4 both in their inwardly folded positions, where they are labelled 200 s-2 f and 200 s 4-f respectively. Whenwall portions 200 s-2 and 200 s-4 are in their inwardly folded positions (200 s-2 f and 200 s-4 f), they facilitate forming a compact shipping module. Whenwall portion 200 s-2 is in its unfolded position (200 s-2 u), it forms withwall portion 200 s-1 awall component 200 proximate firsttransverse edge 108, and whenwall portion 200 s-4 is in its unfolded position (200 s-4 u), it forms withwall portion 200 s-3 awall component 200 proximate secondtransverse edge 110. - C. Unpartitioned Wall Components
- As compared to the two
wall components 200 proximate first and secondtransverse edges wall components 200 proximate first and secondlongitudinal edges wall components 200, which is sometimes denominated 200P in this disclosure, and which is located onfloor portion 300 b proximate firstlongitudinal edge 106, is pivotally secured tofloor portion 300 b to permitwall component 200P to pivot abouthorizontal axis 105 shown inFIG. 3 from a folded position to an unfolded position. Pivotally securingwall component 200P also facilitates forming acompact shipping module 15. The remainingwall component 200, sometimes denominated 200R in this disclosure, is rigidly secured onfloor portion 300 a proximate secondlongitudinal edge 116 and abutting the vertical edges offirst wall portion 200 s-1 andthird wall portion 200 s-3 proximate to secondlongitudinal edge 116, as shown inFIG. 2 . - Typically,
structure 150 will utilize onefloor component 300; thusfloor component 300 generally is the full floor ofstructure 150. - A. General Description
-
Floor component 300 has a generally rectangular perimeter. The length and width offloor component 300 can vary in accordance with design preference. In the particular embodiment ofstructure 150 depicted inFIGS. 1B and 2 ,floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m). -
Floor component 300 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to whichfloor component 300 may be subject. - B. Floor Partitioning
- The
floor component 300 is partitioned intofloor portion 300 a andfloor portion 300 b.FIG. 2 shows flowportions floor portions floor portion 300 a adjoiningfloor portion 300 b. - Referring to structure 150 shown in
FIG. 2 ,floor portion 300 a is fixed in position relative tofirst wall portion 200 s-1,third wall portion 200 s-3 andwall component 200R.Floor portion 300 a is joined with hinge structures tofloor portion 300 b, so as to permitfloor portion 300 b to pivot through approximately ninety degrees (90°) of arc about ahorizontal axis 305, generally located as indicated inFIG. 3 , proximate the top surface offloor component 300, between a fully folded position, wherefloor portion 300 b is vertically oriented as shown inFIG. 3 , and the fully unfolded position shown inFIG. 2 , wherefloor portion 300 b is horizontally oriented and co-planar withfloor portion 300 a. - Typically,
structure 150 will utilize oneroof component 400; thusroof component 400 generally is the full roof ofstructure 150. - A. General Description
-
Roof component 400 has a generally rectangular perimeter.FIG. 1B depictsroof component 400. The length and width ofroof component 400 can vary in accordance with design preference. In the particular embodiment ofstructure 150 depicted inFIG. 1B , the length and width ofroof component 400 approximates the length and width offloor component 300. -
Roof component 400 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to whichroof component 400 may be subject. - B. Roof Partitioning
- The
roof component 400 ofstructure 150 is partitioned intoroof portions FIGS. 1A and 3 when folded, and inFIG. 1B when unfolded. Each of theroof portions roof portion 400 a adjoiningroof portion 400 b, androof portion 400 b adjoiningroof portion 400 c. - In the
shipping module 15 shown inFIG. 3 ,roof portions roof component 400 b stacked on top ofroof component 400 a, androof component 400 c stacked on top of theroof component 400 b. As can be appreciated fromFIG. 3 ,roof portion 400 a is fixed in position relative tofirst wall portion 200 s-1,third wall portion 200 s-3 andwall component 200R. Thus to realize the accordion folded configuration shown inFIG. 3 roof portion 400 a is joined toroof portion 400 b with hinge structures that are adapted to permitroof portion 400 b to pivot through up to one hundred and eighty degrees (180°) of arc about ahorizontal axis 405 a (seeFIG. 3 ) between the roof fully folded position shown inFIGS. 1A and 3 , whereroof portion 400 b lies stacked flat againstroof portion 400 a, and the fully unfolded position shown inFIG. 1B . In turn,roof portion 400 b is joined toroof portion 400 c with hinge structures that are adapted to permitroof portion 400 c to pivot through up to one hundred and eighty degrees (180°) of arc about ahorizontal axis 405 b (seeFIG. 3 ) between the folded position shown inFIGS. 1A and 3 , whereroof portion 400 c lies stacked flat againstroof portion 400 b (whenroof portion 400 b is positioned to lie flat againstroof portion 400 a), and the fully unfolded position shown inFIG. 1B . - Referring to
FIG. 2 ,structure 150 includes a fixedspace portion 102 defined byroof component 400 a (shown inFIG. 3 ),floor component 300 a,wall component 200R,wall portion 200 s-1 andwall portion 200 s-3. (Fixedspace portion 102 is also shown edge-on in theshipping module 15 depicted inFIG. 3 ). It is preferred that the fixedspace portion 102 be fitted out during manufacture with internal components, such as kitchens, bathrooms, closets, storage areas, corridors, etc., so as to be in a relatively finished state prior to shipment ofshipping module 15. Also, in the embodiment shown inFIGS. 1A, 1B and 2 ,wall components 200 are fitted during manufacture and prior to shipment with all necessary door and window assemblies, with theenclosure components 155 being pre-wired for electrical needs. - Carrying out the foregoing steps prior to shipment permits the builder, in effect, to erect a largely finished structure simply by “unfolding” (deploying) the positioned components of
shipping module 15. - It is preferred that there be a specific dimensional relationship among
enclosure components 155. -
FIG. 2 shows a top schematic view ofstructure 150 shown inFIGS. 1A and 1B , and includes a geometrical orthogonal grid for clarity of explaining the preferred dimensional relationships among itsenclosure components 155. The basic length used for dimensioning is indicated as “E” inFIG. 2 ; the orthogonal grid overlaid inFIG. 2 is 4E long and 4E wide; notably, theentire structure 150 preferably is bounded by this 4E by 4E orthogonal grid. -
Roof portions FIG. 3 ,roof portion 400 c can be dimensioned to be larger than either ofroof portion 400 a androof portion 400 b in the transverse direction to reduce the chances of binding during the unfolding ofroof portions roof portion 400 c in the foregoing manner are described in U.S. Non-Provisional application Ser. No. 17/569,962, entitled “Improved Folding Roof Component,” filed on Jan. 6, 2022. In addition, as described in U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” filed on Feb. 10, 2020 and now U.S. Pat. No. 11,220,816, as well as in U.S. Non-Provisional application Ser. No. 17/569,962 mentioned above, friction-reducing components can be used to facilitate unfoldingroof component 400, such as by positioning a first wheel caster at the leading edge ofroof portion 400 c proximate to the corner ofroof portion 400 c that is supported bywall portion 200 s-2 asroof portion 400 c is deployed, and by positioning a second similar wheel caster at the leading edge ofroof portion 400 c proximate to the corner ofroof portion 400 c that is supported bywall portion 200 s-4 asroof portion 400 c is deployed. - In
FIG. 2 , the fourwall components 200 are each approximately 4E long, and each ofroof portions Roof portion 400 c is approximately 4E long and 1.45E wide. InFIGS. 2 and 3 , each offloor components floor component 300 a is just over 1.5E wide andfloor component 300 b is just under 2.5E wide. - As shown in
FIG. 2 ,fourth wall portion 200 s-4 is folded inward and positioned generally against fixedspace portion 102, andsecond wall portion 200 s-2 is folded inward and positioned generally againstfourth wall portion 200 s-4 (wall portions 200 s-2 and 200 s-4 are respectively identified inFIG. 2 asportions 200 s-2 f and 200 s-4 f when so folded and positioned). The threeroof components FIG. 1B and shown folded (stacked) inFIG. 3 , withroof component 400 b stacked on top ofroof component 400 a, androof component 400 c stacked on top of theroof component 400 b.Wall component 200P, shown inFIGS. 2 and 3 , is pivotally secured tofloor portion 300 b at the location ofaxis 105, and is vertically positioned against the outside ofwall portions 200 s-2 and 200 s-4. In turn,floor portion 300 b is vertically positioned proximate fixedspace portion 102, withwall component 200P pending fromfloor portion 300 b betweenfloor portion 300 b andwall portions 200 s-2 and 200 s-4. - Sizing the
enclosure components 155 ofstructure 150 according to the dimensional relationships disclosed above yields acompact shipping module 15, as can be seen from the figures. Thus shippingmodule 15 depicted inFIG. 3 , when dimensioned according to the relationships disclosed herein using an “E” dimension (seeFIG. 2 ) of 57 inches (144.8 cm), and when its components are stacked and positioned as shown inFIG. 3 , has an overall length of approximately 19 feet (5.79 m), an overall width of approximately 8.5 feet (2.59 meters) and an overall height of approximately 12.7 feet (3.87 meters). These overall dimensions are less than a typical shipping container. - Each of the wall, floor and
roof components shipping module 15. Alternatively or in addition, theentire shipping module 15 can be sheathed in a protective film. Such protective films can remain in place until after theshipping module 15 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing. - The
shipping module 15 is shipped to the building site by appropriate transport means. One such transport means is disclosed in U.S. Non-Provisional application Ser. No. 16/143,628, filed Sep. 27, 2018 and now U.S. Pat. No. 11,007,921, issued May 18, 2021; the contents of that U.S. Non-Provisional application Ser. No. 16/143,628, filed Sep. 27, 2018, are incorporated by reference as if fully set forth herein, particularly as found at paragraphs 0020-0035 and inFIGS. 1A-2D thereof. As an alternative transport means,shipping module 15 can be shipped to the building site by means of a conventional truck trailer or a low bed trailer (also referred to as a lowboy trailer), and in the case of over-the-water shipments, by ship. - At the building site,
shipping module 15 is positioned over its desired location, such as over a prepared foundation; for example, a poured concrete slab, a poured concrete or cinder block foundation, sleeper beams or concrete posts or columns. This can be accomplished by using a crane, either to liftshipping module 15 from its transport and move it to the desired location, or by positioning the transport means over the desired location, liftingshipping module 15, then moving the transport means from the desired location, and then loweringshipping module 15 to a rest state at the desired location. Particularly suitable equipment and techniques for facilitating the positioning of ashipping module 15 at the desired location are disclosed in U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, now U.S. Pat. No. 11,220,816. The contents of that U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at ¶¶126-128 and in connection withFIGS. 11A and 11B thereof. - Following positioning of
shipping module 15 at the building site, the appropriate portions of wall, floor androof components structure 150. Unfolding occurs in the following sequence: (1)floor portion 300 b is pivotally rotated about horizontal axis 305 (shown inFIG. 3 ) to an unfolded position, (2)wall component 200P is pivotally rotated about horizontal axis 105 (the general location of which is shown inFIG. 3 ) to an unfolded position, (3)wall portions 200 s-2 and 200 s-4 are pivotally rotated aboutvertical axes 192 and 194 (shown inFIG. 2 ) respectively to unfolded positions, and (4)roof portions horizontal axes FIG. 3 ) respectively to unfolded positions. - After unfolding, the
enclosure components 155 are secured together to finish thestructure 150 that is shown inFIG. 1A . During or after unfolding and securing of theenclosure components 155, any remaining finishing operations are performed, such as addition of roofing material, and making hook-ups to electrical, fresh water and sewer lines to completestructure 150, as relevant here. - The foregoing detailed description is for illustration only and is not to be deemed as limiting the inventions disclosed herein, which are defined in the appended claims.
Claims (20)
1. An enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising:
a first structural layer having a first face, an opposed second face and comprising a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline in a side-by-side relationship with a second structural panel of magnesium oxide;
a core layer having a first face, an opposed second face and comprising a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, and with a second edge of the foam spline opposed to the first edge of the foam spline in a side-by-side relationship with a second foam panel, with the first face of the core layer bonded to the second face of the first structural layer;
a first lap joint spline of magnesium oxide, positioned between the first extension spline of the first structural layer and the first face of the core layer, and joining the first and second structural panels of the first structural layer;
a second structural layer having a first face, an opposed second face and comprising a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, and with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, with the second face of the core layer bonded to the first face of the second structural layer;
a second lap joint spline of magnesium oxide, positioned between the second extension spline of the second structural layer and the second face of the core layer, and joining the first and second structural panels of the second structural layer.
2. The enclosure component of claim 1 , wherein the second extension spline is proximate to the foam spline in a superposed relationship.
3. The enclosure component of claim 2 , wherein the first extension spline is distal from the foam spline.
4. The enclosure component of claim 3 , wherein a surface of the first foam panel coinciding with the first face of the core layer includes a recess to receive the first extension spline.
5. The enclosure component of claim 4 , wherein a portion of the first foam panel adjacent to the second face of the core layer and proximate to the first edge of the foam spline defines a recess to receive a first edge of the second lap joint spline, and a portion of the second foam panel adjacent to the second face of the core layer and proximate to the second edge of the foam spline defines a second recess to receive a second edge of the second lap joint spline opposed to the first edge of the second lap joint spline.
6. The enclosure component of claim 1 , further comprising a rigid beam within the foam spline, the rigid beam having a first surface that is coplanar with the second face of the core layer.
7. The enclosure component of claim 6 , comprising a channel formed within the foam spline proximate to a second surface of the rigid beam, wherein the channel is opposed to the first surface of the rigid beam and distal from the second face of the core layer.
8. The enclosure component of claim 1 , wherein the foam spline comprises a series of keys along the first edge of the foam spline and along the second edge of the foam spline.
9. The enclosure component of claim 8 , wherein the first foam panel comprises slots at first and second abutting edges, and wherein the second foam panel comprises slots at first and second abutting edges.
10. The enclosure component of claim 9 , wherein the series of keys along the first edge of the foam spline are configured to be received by the slots at the first abutting edge of the first foam panel, and wherein the series of keys along the second edge of the foam spline are configured to be received by the slots at the second abutting edge of the second foam panel, to mate the first foam panel and the second foam panel to opposing sides of the foam spline.
11. The enclosure component of claim 1 , wherein the foam spline comprises a rigid beam disposed therein and extending a length of the foam spline.
12. The enclosure component of claim 11 , wherein the foam spline comprises a channel disposed adjacent to the rigid beam and extending the length of the foam spline.
13. The enclosure component of claim 1 , wherein the first lap joint spline is positioned under the first extension spline.
14. The enclosure component of claim 1 , wherein the first lap joint spline defines a width dimensioned greater than a width of the first extension spline.
15. The enclosure component of claim 1 , wherein the first lap joint spline underlies the first extension spline and at least a portion of each of the first structural panel and the second structural panel.
16. The enclosure component of claim 1 , wherein the first face of the core layer comprises a recess formed therein, the recess dimensioned equally to a thickness of the first lap joint spline to receive the first lap joint spline such that the second face of the first structural layer lies flat against the first face of the core layer.
17. The enclosure component of claim 1 , wherein the first structural layer is disposed against the first face of the core layer and the second structural layer is disposed against the second face of the core layer.
18. The enclosure component of claim 17 , wherein a position of the first lap joint spline at the first face of the core layer is offset a distance along the core layer from a position of the second lap joint spline at the second face of the core layer.
19. The enclosure component of claim 17 , wherein seams of the first lap joint spline with the first structural layer do not match to corresponding seams of the second lap joint spline with the second structural layer across a thickness of the core layer due to the offset.
20. The enclosure component of claim 17 , wherein seams of the first structural layer do not match to corresponding seams of the second structural layer across a thickness of the core layer.
Priority Applications (1)
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US18/220,333 US20240018779A1 (en) | 2022-07-12 | 2023-07-11 | Universal panel |
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US202263388366P | 2022-07-12 | 2022-07-12 | |
US18/220,333 US20240018779A1 (en) | 2022-07-12 | 2023-07-11 | Universal panel |
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US20240018779A1 true US20240018779A1 (en) | 2024-01-18 |
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US18/220,333 Pending US20240018779A1 (en) | 2022-07-12 | 2023-07-11 | Universal panel |
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WO (1) | WO2024015355A1 (en) |
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US4671038A (en) * | 1986-04-30 | 1987-06-09 | Porter William H | Roof sandwich panel juncture running with the pitch |
US8844243B1 (en) * | 2013-03-06 | 2014-09-30 | Jerry GILLMAN | Method of connecting structural insulated building panels through connecting splines |
SE1650571A1 (en) * | 2016-04-29 | 2017-10-30 | Zenergy Ab | Fire resistant construction panel element system |
US10494813B2 (en) * | 2016-08-26 | 2019-12-03 | Kps Global Llc | System and method for affixing insulated panels |
US11840836B2 (en) * | 2019-07-26 | 2023-12-12 | Viken Ohanesian | Structural wall panel system |
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2023
- 2023-07-11 WO PCT/US2023/027363 patent/WO2024015355A1/en unknown
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