US20240060291A1 - Subassembly for enclosure component manufacture - Google Patents
Subassembly for enclosure component manufacture Download PDFInfo
- Publication number
- US20240060291A1 US20240060291A1 US18/232,884 US202318232884A US2024060291A1 US 20240060291 A1 US20240060291 A1 US 20240060291A1 US 202318232884 A US202318232884 A US 202318232884A US 2024060291 A1 US2024060291 A1 US 2024060291A1
- Authority
- US
- United States
- Prior art keywords
- edge
- edges
- component
- panel
- enclosure component
- 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
- 238000004519 manufacturing process Methods 0.000 title claims description 37
- 239000006260 foam Substances 0.000 claims abstract description 270
- 239000002344 surface layer Substances 0.000 claims abstract description 92
- 239000012792 core layer Substances 0.000 claims abstract description 88
- 230000002787 reinforcement Effects 0.000 claims abstract description 55
- 238000005520 cutting process Methods 0.000 claims description 27
- 238000005304 joining Methods 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 17
- 229910000831 Steel Inorganic materials 0.000 claims description 11
- 239000010959 steel Substances 0.000 claims description 11
- 239000004568 cement Substances 0.000 claims description 6
- 239000000853 adhesive Substances 0.000 description 30
- 230000001070 adhesive effect Effects 0.000 description 30
- 238000010276 construction Methods 0.000 description 29
- 230000000712 assembly Effects 0.000 description 13
- 238000000429 assembly Methods 0.000 description 13
- 238000007789 sealing Methods 0.000 description 13
- 229920002635 polyurethane Polymers 0.000 description 12
- 239000004814 polyurethane Substances 0.000 description 12
- 239000000463 material Substances 0.000 description 7
- 239000010410 layer Substances 0.000 description 6
- 238000004891 communication Methods 0.000 description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 4
- 239000000395 magnesium oxide Substances 0.000 description 4
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 4
- 238000009428 plumbing Methods 0.000 description 4
- 230000037361 pathway Effects 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- 238000000638 solvent extraction Methods 0.000 description 3
- 101150114976 US21 gene Proteins 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
- 239000000835 fiber Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 241001669679 Eleotris Species 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000009429 electrical wiring Methods 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 239000013505 freshwater Substances 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- -1 wooden boards Substances 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
- E04B1/344—Structures characterised by movable, separable, or collapsible parts, e.g. for transport with hinged parts
- E04B1/3442—Structures characterised by movable, separable, or collapsible parts, e.g. for transport with hinged parts folding out from a core cell
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
- E04B1/344—Structures characterised by movable, separable, or collapsible parts, e.g. for transport with hinged parts
- E04B1/3445—Structures characterised by movable, separable, or collapsible parts, e.g. for transport with hinged parts foldable in a flat stack of parallel panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
- E04B1/34384—Assembling details for foldable, separable, collapsible or retractable 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.
- the enclosure component has a length, a width and a thickness and comprises a first surface layer having a first face and an opposed second face, a core layer having a first face and an opposed second face, and a second surface layer having a first face and an opposed second face.
- the core layer comprises a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel.
- Each of the first, second and third foam panels has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges.
- the first and second edges of the first, second and third foam panels are oriented along the length of the enclosure component.
- the first and second edges of each of the second and third foam panels each has a same first linear dimension
- the third and fourth edges of each of the second and third foam panels each has a same second linear dimension.
- the second and third foam panels each has (a) an internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges.
- the fourth edge of the first panel is arranged in a side-by-side relationship with the third edge of the second panel, and the third edge of the first panel arranged in a side-by-side relationship with the third edge of the third panel.
- the second face of the first surface layer is bonded to the first face of the core layer
- the first face of the second surface layer is bonded to the second face 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 side view of the laminate structure design of the present inventions.
- FIG. 5 is an exploded perspective view of an enclosure component workpiece of the present inventions.
- FIG. 6 is a cutaway perspective view of the core layer of the present inventions.
- FIG. 7 is a perspective view of an enclosure component workpiece of the present invention at one stage of being manufactured to form a wall component.
- FIG. 8 is a perspective view of an enclosure component showing a cutaway of the core layer of two workpieces used to form the enclosure component of the present inventions.
- FIG. 9 A is a perspective view of a foldable I-beam for a floor component in accordance with the present inventions, in the beam unfolded position
- FIG. 9 B is a side view of a foldable I-beam for a floor component in accordance with the present inventions, in the beam folded position.
- FIG. 10 is a cutaway perspective view showing the placement of floor end hinge assemblies in the structure of a floor component in accordance with the present inventions.
- FIG. 11 A is a perspective view of a foldable I-beam for a roof component in accordance with the present inventions, in the beam unfolded position
- FIG. 11 B is a side view of a foldable I-beam for a roof component in accordance with the present inventions, in the beam folded position.
- FIG. 12 is a cutaway perspective view showing the placement of roof end hinge assemblies in the structure of a roof component in accordance with the present inventions.
- FIG. 13 is perspective view providing a schematic illustration of the assembly of the major portions of a floor component of the present inventions.
- FIG. 14 is perspective view providing a schematic illustration of the assembly of the major portions of a roof component of the present inventions.
- FIG. 15 A is a perspective view of a joinder spline of the present inventions
- FIG. 15 B is a detailed perspective view of the barbs optionally provided on one or more joinder splines of the present inventions.
- FIGS. 1 through 3 An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in FIGS. 1 through 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 embodiment of structure 150 shown in FIG. 1 B is square in shape, approximately 19 feet (5.79 m) by 19 feet (5.79 m), although embodiments of the structure 150 can have different dimensions.
- FIG. 2 shows a top schematic view of structure 150 shown in FIG. 1 B , and includes a geometrical orthogonal grid, which is used to assist in the lay-out and assembly of the elements forming structure 150 , as well as 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, with the mid-point grid line in the longitudinal direction designated as G L and the mid-point grid line in the transverse direction designated as G T (in this disclosure, reference simply to grid line “G” should be understood to refer to either).
- dimension “E” is 57 inches (144.8 cm), although embodiments of the structure 150 can have different “E” dimensions. The use of this grid system will be described further below.
- 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 multi-layered, laminate design generally shown in FIG. 4 .
- the elements of this multi-layered, laminate design comprise a core layer 160 , a first surface layer 210 and a second surface layer 215 .
- i 2 . . m
- m number of first surface panels 211 are arranged in a side-by-side, contacting relationship (first surface panel 211 k , first surface panel 211 k +1, where 1 ⁇ k ⁇ m) to form a first surface layer 210 of arbitrary length.
- An elongate planar rectangular joinder spline 213 overlaps the kth first surface panel 211 k and the adjacent k+1th surface panel 211 k+1 .
- Joinder spline 213 is shown in FIG. 15 A .
- Each joinder spline 213 underlies a narrow portion of each of the adjacent first surface panels 211 k , 211 k+1 .
- First surface panels 211 can be for example fiber cement board or magnesium oxide (MgO) board.
- the joinder splines 213 can be steel strip stock. Joinder splines 213 can be fastened to first surface panels 211 by adhesive, mechanical fasteners or a combination thereof.
- Second surface layer 215 has a construction similar to first surface layer 210 .
- n number of second surface panels 216 are arranged in a side-by-side, contacting relationship (second surface panel 216 k , second surface panel 216 k+1 , where 1 ⁇ k ⁇ n) to form a second surface layer 215 of arbitrary length.
- joinder spline 217 overlaps the kth second surface panel 216 k and the adjacent k+1th second surface panel 216 k+1 .
- Joinder spline 217 in the described embodiment is the same as joinder spline 213 (but need not be), and is also shown in FIG. 15 A .
- Each joinder spline 217 underlies a narrow portion of each of the adjacent second surface panels 216 k , 216 k+1 .
- Second surface panels 216 can be for example fiber cement board or magnesium oxide (MgO) board.
- the joinder splines 217 can be steel strip stock.
- Joinder splines 217 can be fastened to second surface panels 216 by a suitable adhesive, preferably a polyurethane based construction adhesive, by mechanical fasteners, or by a combination thereof.
- Core layer 160 is sandwiched between first surface layer 210 and second surface layer 215 .
- p number of foam panels 214 are arranged in a side-by-side, contacting relationship (foam panel 214 k , foam panel 214 k+1 , where 1 ⁇ k ⁇ p) to form a planar core layer 160 of arbitrary length, collectively presenting a planar first face and an opposing planar second face.
- the first face of core layer 160 is bonded to first surface layer 210 using for example a suitable adhesive, preferably a polyurethane based construction adhesive, and the second face of core layer 160 is bonded to second surface layer 215 using for example a suitable adhesive, preferably a polyurethane based construction adhesive.
- a suitable adhesive preferably a polyurethane based construction adhesive
- Foam panels 214 are made for example of expanded polystyrene (EPS) or polyurethane foam.
- reinforcement splines 221 are additionally provided a plurality of planar elongate reinforcement splines 221 spaced-apart across the length of core layer 160 , as shown in FIGS. 4 and 5 .
- Reinforcement splines 221 are received in recesses 222 cut into foam panels 214 to permit the second surface panels 216 to lie flat against core layer 160 .
- Reinforcement splines 221 are made for example of lumber.
- Reinforcement splines 221 improve the bending resistance of the enclosure component 155 .
- reinforcement splines 221 are provided on only one face of core layer 160 , and preferably are disposed on the face that is distal from the interior of the structure 150 .
- reinforcement splines 221 can be provided in recesses 222 on both faces of core layer 160 .
- joinder splines 213 and 217 do not overlie the seams 218 , but rather are offset a select distance so that the seams between and in each of the first surface layer 210 and second surface layer 215 do not match up with the seams 218 of core layer 216 across the thickness of enclosure component 155 .
- 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.
- Structure 150 comprises a number of wall, floor and roof components with abutting or exposed exterior edges, as well as a number of partitioned wall, floor and roof components with interior edges.
- sealing structures can be utilized, with the objective to limit or prevent the ingress of rain water, noise and outside air across these exterior and interior edges into the interior of structure 150 .
- enclosure components 155 it is necessary to transfer the loads imposed on their surfaces to their exterior edges, where those loads can be transferred either to or through adjoining walls, or to the building foundation.
- loads include the weight of equipment, furniture and people borne by their surfaces, as well as vertical seismic loads.
- loads include those arising from meteorological conditions (hurricanes, tornadoes, etc.) and human action (vehicle and other object impacts).
- multi-layered, laminate design shown in FIG. 4 will function to transfer the loads described above.
- structural members such as beams and/or joists, can be utilized within the perimeter of the enclosure components 155 , as is deemed appropriate to the specific design of structure 150 and the particular enclosure component 155 , to assist in the transfer of loads to the exterior edges.
- each enclosure component 155 that is to say, all wall components 200 , all floor components 300 and all roof components 400 —be fabricated from a common subassembly, referred to herein as enclosure component workpiece 250 .
- first and second surface layers 210 , 215 can be cement board
- joinder splines 213 , 217 can be steel strip
- reinforcement spline 221 can be lumber.
- the workpiece 250 in the FIG. 5 embodiment uses six planar rectangular first surface panels 211 for first surface layer 210 .
- Four of these first surface panels 211 have the same width and length (X, Y direction respectively in FIG. 5 ), and are designated “ 211 - 1 ” in FIG. 5 .
- the remaining two of the six first surface panels 211 designated “ 211 - 2 ” in FIG. 5 , each has the same length as first surface panels 211 - 1 , but is smaller in width than first surface panels 211 - 1 .
- Each first surface panel 211 - 2 of the workpiece 250 has the same length and width as the other first surface panel 211 - 2 . Accordingly, from a manufacturing standpoint two stock keeping units, or SKUs, can be utilized to form the first surface layer 210 of the workpiece 250 .
- the workpiece 250 in the FIG. 5 embodiment also uses six planar rectangular second surface panels 216 for second surface layer 215 .
- Four of these second surface panels 211 have the same length and width, and are designated “ 216 - 1 ” in FIG. 5 .
- the remaining two of the six second surface panels 216 designated “ 216 - 2 ” in FIG. 5 , each has the same length as first surface panels 216 - 1 , but is smaller in width than first surface panels 216 - 1 .
- Each second surface panel 216 - 2 of the workpiece 250 has the same length and width as the other second surface panel 216 - 2 . Accordingly, from a manufacturing standpoint two SKUs can be utilized to form the second surface layer 215 of the workpiece 250 .
- each first surface panel 211 can be 114 inches (2.9 m) long (Y direction in FIG. 5 ), and that each second surface panel 216 also can be 114 inches (2.9 m) long.
- first surface panels 211 be provided in two widths (X direction in FIG. 5 ).
- first width 48 inches (1.22 m) for first surface panel 211 - 1
- second width 18 inches (0.46 m) for first surface panel 211 - 2
- second surface panels 216 also be provided in two widths.
- first width of 48 inches (1.22 m) for second surface panel 216 - 1 there can be a first width of 48 inches (1.22 m) for second surface panel 216 - 1
- second width of 18 inches (0.46 m) for second surface panel 216 - 2 First surface panels 211 and second surface panels 216 can be for example 0.3125 in (0.7938 cm) thick cement board.
- first surface layer 210 and second surface layer 215 are made of the same material, then the first and second surface layers 210 , 215 of workpiece 250 can be fabricated using but two SKUs.
- the workpiece 250 additionally uses five planar rectangular foam panels 214 for core layer 160 , each preferably having the same length (Y-direction in FIG. 5 ) as surface panels 211 , 216 ; thus if surface panels 211 , 216 are 114 inches (2.9 m) long, then foam panels preferably are 114 inches (2.9 m) long.
- Each of the foam panels 214 is provided with one or more elongate vertically-oriented internal passageways extending parallel to the y-axis, referred to as vertical chases 219 , spanning the distance between their top and bottom edges. Vertical chases 219 facilitate the installation of utility lines.
- the foam panels 214 in the depicted embodiment are also provided with one or more horizontal internal passageways, referred to as horizontal chases 207 , which span the width of foam panels 214 .
- the horizontal chases 207 extend parallel to the X-axis in FIG. 5 , perpendicular to the Y-axis, and generally in the same plane as the vertical chases 219 such that and the horizontal chases 207 intersect vertical chases 219 .
- Horizontal chases 207 facilitate wiring across enclosure component 155 .
- the vertical chases 219 and horizontal chases 207 are formed in and completely surrounded by the foam of the foam panels along their lengths, except that the ends of the vertical chases 219 and horizontal chases 207 can be accessible at one or more edges of the work piece 250 and/or the vertical chases 219 and horizontal chases 207 can be accessed via any cutout formed in the workpiece 250 .
- Reference to vertical, horizontal, top and bottom with respect to the workpiece 250 is provided to illustrate a relative relationship of the components that form the workpiece 250 as it is illustrated in FIGS. 5 and 6 , not necessarily relative to the shipping module 15 or structure 1250 .
- the workpieces 250 can be utilized to form a wall component 200 , a floor component 300 , and a roof component 400 , the orientation of the workpieces will vary.
- vertical chases 219 and horizontal chases 207 in foam panels 214 are shown in the cross-section of core layer 160 of FIG. 6 taken along the X-Y axis. It is preferred that vertical chases 219 be uniformly spaced apart a distance equal to 0.5E, which in the embodiment shown is a distance of 28.5 inches (72.4 cm). It is additionally preferred that one of the vertical chases 219 , denominated 219 C in FIG. 6 , be positioned at the X-direction mid-length point of core layer 160 (see FIG. 6 ), and that the remaining chases 219 be spaced outward 0.5E to each side of that mid-length point vertical chase 219 C .
- horizontal chases 207 there be an even number of horizontal chases 207 symmetrically placed above and below the Y-direction mid-length point of core layer 160 ; in the embodiment shown in FIG. 6 , there are two such horizontal chases 207 in core layer 160 .
- the first such horizontal chase 207 can be positioned 16 inches (40.6 cm) above the bottom edge of core layer 160 (Y direction in FIG. 6 )
- the second such horizontal chase 207 can be positioned 16 inches (40.6 cm) below the top edge of core layer 160 .
- the horizontal chases 207 in each of the adjacent foam panels 214 are aligned to provide a path of communication across the length (X direction in FIG. 6 ) of the workpiece 250 .
- the vertical and horizontal passageways in foam panels 214 defining vertical and horizontal chases 219 and 207 preferably are formed prior to assembly of foam panels 214 into the laminate multi-layer structure of workpiece 250 .
- These passages can be formed for example by use of a hot wire shaped and directed to form within panels 214 a cylindrical or other desired closed shape, thereby forming a foam plug severed from the bulk foam. Removal of the foam plug yields the desired passageway defining a vertical chase 219 or a horizontal chase 207 .
- Each chase 207 , 219 preferably is provided with a diameter sufficient to permit the installation of utility lines.
- the vertical chase 219 in each foam panel 214 - 3 designated 219 W in FIG. 6 , can be made larger in cross-section than the vertical chases in other locations.
- the two horizontal chases 207 shown running through the foam panels 214 each has the same area in cross-section as vertical chases 219 W.
- each vertical chase 219 W has an oval shape with a major diameter for example of approximately 5 inches (12.7 cm)
- each horizontal chase 207 in foam panels 214 - 1 , 214 - 2 and 214 - 3 has an oval shape with a major diameter of approximately 5 inches (12.7 cm).
- each of the vertical chases 219 in foam panels 214 - 1 and 214 - 2 has a circular shape with a diameter of approximately 1.5 inches (3.8 cm).
- a loop pathway, utility service sub-system 460 can be traced through vertical chases 219 W and horizontal chases 207 in the foam panels 214 (shown as a dashed line in FIG. 6 ), which sub-system is generally located about the periphery of work piece 250 , and through which utility trunk lines can be conveniently routed and connected to service lines.
- the recesses 222 that will receive reinforcement splines 221 . It is preferred that the recesses 222 be uniformly spaced apart a distance equal to E, which in the embodiment shown is a distance of 57 inches (145 cm). It is additionally preferred that the recesses 222 (and the reinforcement splines 221 therein) be symmetrically positioned to each side of the X-direction mid-point of core layer 160 .
- the X-direction mid-point of one of these foam panels 214 is positioned to coincide with the X direction mid-point (in FIG. 5 ) of the workpiece 250 .
- the width of foam panel 214 - 1 in the FIG. 5 embodiment is 48 inches (1.22 m).
- foam panel 214 - 1 preferably is symmetric about its “X” and “Y” axes; i.e., the vertical chase 219 and horizontal chases 207 in foam panel 214 - 1 are symmetrically located within foam panel 214 - 1 about the X, Y axes bisecting foam panel 214 - 1 .
- workpiece 250 includes only one foam panel 214 - 1 .
- vertical chase 219 C will coincide with one of the mid-point grid lines G, the particular one (G L or G T ) depending upon the enclosure component 155 in which the workpiece 250 is used.
- each foam panel 214 - 2 is symmetric about its X axis, but not about its Y axis; i.e., the horizontal chases 207 in foam panel 214 - 2 are symmetrically located about the X axis bisecting foam panel 214 - 2 (and align with the horizontal chases 207 in foam panel 214 - 1 ), but the vertical chases 219 are not symmetrically located about the Y axis bisecting foam panel 214 - 2 .
- the width of foam panel 214 - 2 is 48 inches (1.22 m).
- There is a first vertical chase 219 located in foam panel 214 - 2 spaced preferably 0.5 E from vertical chase 219 C , which in the embodiment depicted is 4.5 inches (11.43 cm) from the edge of foam panel 214 - 2 abutting foam panel 214 - 1 .
- there is a second vertical chase 219 located in foam panel 214 - 2 spaced preferably E from vertical chase 219 C , which in the embodiment depicted is thirty three inches (83.8 cm) from the edge of foam panel 214 - 2 abutting foam panel 214 - 1 .
- a recess 222 which after assembly of work piece 250 preferably is located a distance E from the X-direction mid-point of foam panel 214 - 1 , which location in the embodiment depicted is 4.5 inches (11.43 cm) from the edge of foam panel 214 - 2 abutting foam panel 214 - 1 .
- This recess 222 when so positioned will overlie the vertical chase 219 located in foam panel 214 - 2 which is preferably spaced 0.5 E from vertical chase 219 C , as can be seen in FIG. 6 .
- one of the foam panels 214 - 2 is rotated 180 degrees (180°) about its Z axis relative to the other of the foam panels 214 - 2 , to result in the vertical chases 219 in foam panels 214 - 2 to be symmetrically located about the Y axis bisecting foam panel 214 - 1 .
- one of the foam panels 214 - 2 in FIG. 5 is designated 214 - 2 U, and the other is designated 214 - 2 D, to reflect their different orientations.
- each foam panel 214 - 3 is symmetric about its X axis, but not about its Y axis; i.e., the horizontal chases 207 in foam panel 214 - 3 are symmetrically located about the X axis bisecting foam panel 214 - 3 (and align with the horizontal chases 207 in foam panel 214 - 2 ), but the vertical chases 219 are not symmetrically located about the Y axis bisecting foam panel 214 - 3 .
- the width of foam panel 214 - 3 is 42 inches (1.07 m).
- a second vertical chase 219 located in foam panel 214 - 3 , spaced preferably 2E from vertical chase 219 C , which in the embodiment depicted is at the exterior edge of foam panel 214 - 3 ; i.e., 42 inches (106.7 cm) from the edge of foam panel 214 - 2 abutting foam panel 214 - 3 .
- a recess 222 which after assembly of work piece 250 preferably is located a distance 1.5E from the Y direction mid-point of foam panel 214 - 1 , which location in the embodiment depicted is 13.5 inches (34.3 cm) from the edge of foam panel 214 - 3 abutting foam panel 214 - 2 .
- This recess 222 when so positioned will overlie the vertical chase 219 located in foam panel 214 - 3 which is also preferably spaced 1.5 E from vertical chase 219 C .
- one of the foam panels 214 - 3 is rotated 180 degrees (180°) about its Z axis (see FIG. 5 ) relative to the other of the foam panels 214 - 3 , to result in the vertical chases 219 in foam panels 214 - 3 to be symmetrically located about the Y axis bisecting foam panel 214 - 1 .
- one of the foam panels 214 - 3 in FIG. 5 is designated 214 - 3 U, and the other is designated 214 - 3 D, to reflect their different orientations.
- first surface panels 211 and second surface panels 216 are 0.3125 in (0.7938 cm) thick, and if the foam panels 214 are made 5.375 in (13.65 cm) thick, then workpiece 250 will have an overall thickness of 6 in (15.24 cm).
- FIG. 5 depicts a number of spaced-apart toe screw apertures 287 in each of the four first surface panels 211 - 1 .
- these apertures 287 can be provided to receive toe screw housings which facilitate fastening the wall component 200 to a floor component 300 .
- a toe screw housing is inserted into a toe screw aperture 287 , following which a fastener, such as a SIP screw, can be inserted and driven into the underlying exterior edge reinforcement of both the wall component 200 and the underlying floor component 300 , to fasten the wall component 200 to the floor component 300 .
- a fastener such as a SIP screw
- the contents of that U.S. Non-Provisional patent application Ser. No. 17/587,051 entitled “Wall Component Appurtenances”, filed Jan. 28, 2022 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of toe screw housing 288 , set forth for example in ⁇ 0048-0055 and in FIGS. 8 A- 8 C thereof.
- Toe screw apertures 287 need not be provided in work pieces 250 intended for use in floor components 300 or roof components 400 .
- toe screw apertures 287 it is desirable for toe screw apertures 287 not to overlie any of the vertical chases 219 , so as to avoid a fastener being driven through for example electrical wiring running through chases 219 .
- the seam between the inner two first surface panels 211 - 1 will overlie the chase 219 C in foam panel 214 - 1 .
- the toe screw apertures 287 will not overlie any of the vertical chases 219 .
- This spacing pattern for toe screw apertures 287 is shown in FIG. 5 .
- the cutting of apertures 287 can be performed on individual panels 211 prior to assembling first surface layer 210 .
- joinder splines 213 , 217 can be steel strip 112 to 114 inches (2.84 to 2.90 m) in length (Y axis in FIG. 5 ), four inches (10.16 cm) in width (X axis in FIG. 5 ) and 0.024 inch (0.061 mm) thick (Z axis in FIG. 5 ).
- reinforcement splines 221 can be lumber 112 to 114 inches (2.84 to 2.90 m) in length (Y axis in FIG. 5 ), 3.5 inches (8.89 cm) in width (X axis in FIG. 5 ) and 1.5 inches (3.81 cm) thick (Z axis in FIG. 5 ).
- the sequence for manufacturing workpiece 250 can proceed in various ways.
- a first manufacturing sequence proceeds as follows:
- a second manufacturing sequence proceeds as follows:
- certain enclosure components 155 can include two identical workpieces 250 joined together along their length by an enclosure component beam assembly 525 (e.g., which can be embodied as floor beam assembly 325 or roof beam assembly 425 described herein) such that the enclosure component beam assembly 525 is positioned between the two workpieces 250 .
- the workpiece 250 can each include the vertical chases 219 and horizontal chases 207 , where vertical chases 219 W and the horizontal chases 207 can define the utility service sub-systems 460 , one in each of the workpieces 250 .
- the workpieces 250 are aligned so that the vertical chases 219 W of each work piece are aligned with each other.
- the beam assembly can include openings 527 that also align with the vertical chases 219 W such that the aligned vertical chases 219 W on opposite sides of the beam assembly can be in communication with each other.
- the vertical chases 219 W and the horizontal chases 207 that are proximate to a periphery of the enclosure component can form a closed path or loop, utility service system 470 that extends through the two workpieces 250 and the beam assembly 525 .
- the enclosure component beam assembly 525 can be formed of multiple beams joined together by one or more hinges (e.g., beam assemblies 325 and 425 ) and the workpieces 250 can be cut along hinge lines to allow the enclosure components to move between a folded position and an unfolded position.
- utility service system 470 is generally located about the periphery of the enclosure component 155 and comprises major portions of the vertical chases 219 W and major portions of the horizontal chases 207 proximate the edges of the enclosure component 155 .
- Utility service system 470 is a pathway through which utility trunk lines can be conveniently routed and connected to service lines, and also provides communication between the two utility service sub-systems 460 in the work pieces 250 .
- wall component 200 floor component 300 , and roof component 400 are provided in the sections following, as well as the further steps to fabricate each of the foregoing using one or more workpieces 250 .
- 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 partitioned wall components 200 , generically denominate 200 s .
- One of the two opposing partitioned wall components 200 s comprises first wall portion 200 s - 1 and second wall portion 200 s - 2
- the other of the two opposing partitioned wall components 200 s 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 greater in length (the dimension in the transverse direction) than the length of 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 in length than the length of 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 s 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 s 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 .
- a workpiece 250 is subject to the following steps:
- a workpiece 250 is subject to the following steps:
- 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 and can be fabricated using one or more workpieces 250 .
- 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).
- 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 FIGS. 2 and 4 , where floor portion 300 b is horizontally oriented and co-planar with floor portion 300 a.
- 90° ninety degrees
- FIG. 9 A shows a floor beam assembly 325 that can be placed within floor component 300 to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne by floor component 300 to its edges.
- Floor beam assembly 325 includes two I-beams 326 a and 326 b .
- I-beam 326 a is positioned approximately in the middle of floor portion 300 a
- I-beam 326 b is positioned approximately in the middle of floor portion 300 b
- each of I-beams 326 a and 326 b is oriented in the transverse direction.
- a hinge assembly 329 A joins I-beam 326 a to I-beam 326 b .
- the hinge assembly 329 A permits floor beam assembly 325 to be folded to a beam folded position shown in FIG. 9 B and unfolded to a beam unfolded position shown in FIG. 9 A .
- the I-beams 326 a and 326 b extend parallel to the transverse direction in the unfolded position. Further, the hinge assembly 329 A can be locked when beam assembly 325 is in the beam unfolded position, which transforms floor beam assembly 325 into a rigid structure that will reinforce floor component 300 in the direction perpendicular to its axis of folding.
- Hinge assembly 329 A comprises two identical hinge assembly portions 330 A partnered together to form a pivoted junction, as shown in FIGS. 9 A and 9 B .
- a detailed description of the construction of hinge assembly 329 A and its hinge assembly portions 330 A is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov.
- hinge assembly 329 A and its hinge assembly portions 330 A set forth for example in ⁇ 0075-0087 and in FIGS. 9 - 12 and 13 C- 13 E thereof.
- floor beam assembly 325 is located at the mid-point between first transverse floor edge 120 and second transverse floor edge 118 , and no hinge assemblies 329 A are utilized elsewhere within floor component 300 , such as proximate to first transverse floor edge 120 and second transverse floor edge 118 . Therefore, to assist in smoothly rotating floor portion 300 b , there is provided adjacent first transverse floor edge 120 a first floor end hinge assembly 345 A joining floor portions 300 a and 300 b , and there is provided adjacent second transverse floor edge 118 a second floor end hinge assembly 345 A joining floor portions 300 a and 300 b . The locations of both first and second floor end hinge assemblies 345 A is indicated in FIG. 10 .
- Floor end hinge assembly 345 A comprises two identical floor end hinge portions 350 A (not specified in the figures).
- a description of the construction of floor end hinge assembly 345 A and its floor end hinge portions 350 A is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov.
- a floor component 300 comprises in substantial part two workpieces 250 joined by a floor beam assembly 325 .
- each workpiece 250 is subject to the following steps:
- 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 and can be fabricated using one or more workpieces 250 .
- 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 FIGS. 1 B, 4 and 5 , the length and width of roof component 400 approximates the length and width of floor component 300 .
- 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 fully 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 .
- FIGS. 11 A and 11 B shows a roof beam assembly 425 that can be placed within roof component 400 to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne by floor component 300 to its edges.
- Roof beam assembly 425 includes three I-beams 426 a , 426 b and 426 c .
- a hinge assembly 429 B joins I-beam 426 a to I-beam 426 b .
- a hinge assembly 429 C joins I-beam 426 b to I-beam 426 c .
- the hinge assemblies 429 B and 429 C permit roof beam assembly 425 to be folded to a beam folded position, shown in FIG. 11 B , and unfolded to a beam unfolded position, shown in FIG. 11 A .
- the I-beams 426 a and 426 b and 426 c extend parallel to the transverse direction in the unfolded position. Further, the hinge assemblies 429 B and 429 C can be locked when roof beam assembly 425 is in the beam unfolded position, which transforms roof beam assembly 425 into a rigid structure that will reinforce roof component 400 in the direction perpendicular to its axes of folding.
- Hinge assembly 429 B comprises two identical hinge assembly portions 430 B partnered together to form a pivoted junction
- hinge assembly 429 C comprises two identical hinge assembly portions 430 C partnered together to form a pivoted junction.
- hinge assembly 429 B and its hinge assembly portions 430 B set forth for example in ⁇ 00106-00118 and in FIGS. 16-19 and 24A thereof
- hinge assembly 429 C and its hinge assembly portions 430 C set forth for example in ⁇ 00119-00126 and in FIGS. 20-23 and 24A-24B thereof.
- roof beam assembly 425 is located at the mid-point between first transverse roof edge 408 and second transverse roof edge 410 , and no hinge assemblies 429 B or 429 C are utilized elsewhere within roof component 400 , such as proximate to first transverse roof edge 408 or second transverse roof edge 410 . Therefore, to assist in smoothly rotating roof portion 400 b relative to roof portion 400 a , there is provided adjacent first transverse roof edge 408 a first roof end hinge assembly 445 B joining roof portions 400 a and 400 b , and there is provided adjacent second transverse roof edge 410 a second roof end hinge assembly 445 B joining roof portions 400 a and 400 b .
- first transverse roof edge 408 a first roof end hinge assembly 445 C joining roof portions 400 b and 400 c
- second transverse roof edge 410 a second roof end hinge assembly 445 C joining roof portions 400 b and 400 c .
- first and second roof end hinge assemblies 445 B are indicated in FIG. 12
- first and second roof end hinge assemblies 445 C are indicated in FIG. 12 .
- Roof end hinge assembly 445 B comprises two identical roof end hinge portions 450 B
- roof end hinge assembly 445 C comprises two identical roof end hinge portions 450 C (roof end hinge portions 450 B, 450 C are not specified in the figures).
- a description of the construction of these roof end hinge assemblies and roof end hinge portions is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov.
- roof end hinge assembly 445 B and its roof end hinge portions 450 B set forth for example in ⁇ 00127-00130 and in FIGS. 25 A- 25 B thereof
- description of the construction of roof end hinge assembly 445 C and its roof end hinge portions 450 C set forth for example in ⁇ 00131-00132 and in FIGS. 24 B and 25 D thereof.
- a roof component 400 comprises in substantial part two workpieces 250 joined by a roof beam assembly 425 .
- each workpiece 250 is subject to the following steps:
- roof beam assembly 425 can be provided with apertures as appropriate locations to permit communication between the vertical chases 219 W in each of the two workpieces 250 .
- utility service system 470 generally located about the periphery of roof component 400 and comprising, in addition to major portions of the vertical chases 219 W, major portions of the horizontal chases 207 proximate the longitudinal and transverse edges of roof component 400 .
- Utility service system 470 is a pathway through which utility trunk lines can be conveniently routed and connected to service lines, and also provides communication between the two utility service sub-systems 460 in the work pieces 250 of roof component 400 .
- 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.
- enclosure components 155 It is preferred that there be a specific dimensional relationship among enclosure components 155 .
- 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.
- each of roof portions 400 a and 400 b is approximately 4E long and 1.25E wide, whereas 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.
- Wall components 200 P and 200 R are approximately 4E long, whereas each of wall components 200 s in the preferred embodiment is approximately 4E long, less the combined thicknesses of wall components 200 P and 200 R, as previously indicated.
- 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 FIGS. 1 A and 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 (the general location of which is shown in FIG. 3 ), 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 FIGS. 1 A and 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 177 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 (see 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.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Panels For Use In Building Construction (AREA)
- Roof Covering Using Slabs Or Stiff Sheets (AREA)
Abstract
An enclosure component having first surface layer, a core layer and a second surface layer. The core layer has three rectangular foam panels, each with a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges. The second and third foam panels are identical, and each has an internal passage between the first and second edges that is offset from the mid-point of the panel, and an elongate recess on a surface of the panel spanning the distance between the first and second edges. The fourth edge of the first panel is arranged side-by-side with the third edge of the second panel, and the third edge of the first panel is arranged side-by-side with the third edge of the third panel. An elongate reinforcement spline is in each recess. The first surface layer is bonded to the core layer, and the second surface layer is bonded to the core layer.
Description
- This application claims the benefit of U.S. Provisional Patent Application No. 63/399,389, which was filed on Aug. 19, 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, significant advancements are 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. The enclosure component has a length, a width and a thickness and comprises a first surface layer having a first face and an opposed second face, a core layer having a first face and an opposed second face, and a second surface layer having a first face and an opposed second face. The core layer comprises a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel. Each of the first, second and third foam panels has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges. The first and second edges of the first, second and third foam panels are oriented along the length of the enclosure component. The first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension. The second and third foam panels each has (a) an internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges. The fourth edge of the first panel is arranged in a side-by-side relationship with the third edge of the second panel, and the third edge of the first panel arranged in a side-by-side relationship with the third edge of the third panel. There is an elongate reinforcement spline in each recess. The second face of the first surface layer is bonded to the first face of the core layer, and the first face of the second surface layer is bonded to the second face 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 side view of the laminate structure design of the present inventions. -
FIG. 5 is an exploded perspective view of an enclosure component workpiece of the present inventions. -
FIG. 6 is a cutaway perspective view of the core layer of the present inventions. -
FIG. 7 is a perspective view of an enclosure component workpiece of the present invention at one stage of being manufactured to form a wall component. -
FIG. 8 is a perspective view of an enclosure component showing a cutaway of the core layer of two workpieces used to form the enclosure component of the present inventions. -
FIG. 9A is a perspective view of a foldable I-beam for a floor component in accordance with the present inventions, in the beam unfolded position, andFIG. 9B is a side view of a foldable I-beam for a floor component in accordance with the present inventions, in the beam folded position. -
FIG. 10 is a cutaway perspective view showing the placement of floor end hinge assemblies in the structure of a floor component in accordance with the present inventions. -
FIG. 11A is a perspective view of a foldable I-beam for a roof component in accordance with the present inventions, in the beam unfolded position, andFIG. 11B is a side view of a foldable I-beam for a roof component in accordance with the present inventions, in the beam folded position. -
FIG. 12 is a cutaway perspective view showing the placement of roof end hinge assemblies in the structure of a roof component in accordance with the present inventions. -
FIG. 13 is perspective view providing a schematic illustration of the assembly of the major portions of a floor component of the present inventions. -
FIG. 14 is perspective view providing a schematic illustration of the assembly of the major portions of a roof component of the present inventions. -
FIG. 15A is a perspective view of a joinder spline of the present inventions, andFIG. 15B is a detailed perspective view of the barbs optionally provided on one or more joinder splines of the present inventions. - An embodiment of the foldable,
transportable structure 150 in which the inventions disclosed herein can be implemented is depicted inFIGS. 1 through 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. 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 embodiment ofstructure 150 shown inFIG. 1B is square in shape, approximately 19 feet (5.79 m) by 19 feet (5.79 m), although embodiments of thestructure 150 can have different dimensions. -
FIG. 2 shows a top schematic view ofstructure 150 shown inFIG. 1B , and includes a geometrical orthogonal grid, which is used to assist in the lay-out and assembly of theelements forming structure 150, as well as 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, with the mid-point grid line in the longitudinal direction designated as GL and the mid-point grid line in the transverse direction designated as GT (in this disclosure, reference simply to grid line “G” should be understood to refer to either). In the embodiment ofstructure 150 shown inFIG. 2 , dimension “E” is 57 inches (144.8 cm), although embodiments of thestructure 150 can have different “E” dimensions. The use of this grid system will be described further below. - 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 multi-layered, laminate design generally shown inFIG. 4 . The elements of this multi-layered, laminate design comprise acore layer 160, afirst surface layer 210 and asecond surface layer 215. -
First surface layer 210 comprises two or more planar rectangular first surface panels 211, m in number, where the ith first surface panel 211 is represented by 211 i, and i=1, 2, . . . m. In the case where i≥2, m number of first surface panels 211 are arranged in a side-by-side, contacting relationship (first surface panel 211 k, first surface panel 211 k+1, where 1<k≤m) to form afirst surface layer 210 of arbitrary length. An elongate planarrectangular joinder spline 213 overlaps the kth first surface panel 211 k and the adjacent k+1th surface panel 211 k+1.Joinder spline 213 is shown inFIG. 15A . Eachjoinder spline 213 underlies a narrow portion of each of the adjacent first surface panels 211 k, 211 k+1. First surface panels 211 can be for example fiber cement board or magnesium oxide (MgO) board. The joinder splines 213 can be steel strip stock. Joinder splines 213 can be fastened to first surface panels 211 by adhesive, mechanical fasteners or a combination thereof. -
Second surface layer 215 has a construction similar tofirst surface layer 210. In particular,second surface layer 215 comprises two or more planar rectangular second surface panels 216, n in number, where the ithsecond surface panel 215 is represented by 215 i, and i=1, 2, . . . n. In the case where i≥2, n number of second surface panels 216 are arranged in a side-by-side, contacting relationship (second surface panel 216 k, second surface panel 216 k+1, where 1<k≤n) to form asecond surface layer 215 of arbitrary length. An elongate planarrectangular joinder spline 217 overlaps the kth second surface panel 216 k and the adjacent k+1th second surface panel 216 k+1.Joinder spline 217 in the described embodiment is the same as joinder spline 213 (but need not be), and is also shown inFIG. 15A . Eachjoinder spline 217 underlies a narrow portion of each of the adjacent second surface panels 216 k, 216 k+1. Second surface panels 216 can be for example fiber cement board or magnesium oxide (MgO) board. The joinder splines 217 can be steel strip stock. Joinder splines 217 can be fastened to second surface panels 216 by a suitable adhesive, preferably a polyurethane based construction adhesive, by mechanical fasteners, or by a combination thereof. -
Core layer 160 is sandwiched betweenfirst surface layer 210 andsecond surface layer 215.Core layer 160 comprises a plurality of generally planar rectangular foam panels 214, p in number, where the ith foam panel 214 is represented by 214 i, and i=1, 2, . . . p. In the case where i≥2, p number of foam panels 214 are arranged in a side-by-side, contacting relationship (foam panel 214 k, foam panel 214 k+1, where 1<k≤p) to form aplanar core layer 160 of arbitrary length, collectively presenting a planar first face and an opposing planar second face. The first face ofcore layer 160 is bonded tofirst surface layer 210 using for example a suitable adhesive, preferably a polyurethane based construction adhesive, and the second face ofcore layer 160 is bonded tosecond surface layer 215 using for example a suitable adhesive, preferably a polyurethane based construction adhesive. There is aseam 218 between adjacent foam panels 214. Foam panels 214 are made for example of expanded polystyrene (EPS) or polyurethane foam. - There are additionally provided a plurality of planar
elongate reinforcement splines 221 spaced-apart across the length ofcore layer 160, as shown inFIGS. 4 and 5 . Reinforcement splines 221 are received inrecesses 222 cut into foam panels 214 to permit the second surface panels 216 to lie flat againstcore layer 160. Reinforcement splines 221 are made for example of lumber. Reinforcement splines 221 improve the bending resistance of theenclosure component 155. In the embodiment shown, reinforcement splines 221 are provided on only one face ofcore layer 160, and preferably are disposed on the face that is distal from the interior of thestructure 150. Optionally, reinforcement splines 221 can be provided inrecesses 222 on both faces ofcore layer 160. - As can be seen in the example of
FIG. 4 , the joinder splines 213 and 217 do not overlie theseams 218, but rather are offset a select distance so that the seams between and in each of thefirst surface layer 210 andsecond surface layer 215 do not match up with theseams 218 of core layer 216 across the thickness ofenclosure component 155. - 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. - E. Enclosure Component Sealing Systems
-
Structure 150 comprises a number of wall, floor and roof components with abutting or exposed exterior edges, as well as a number of partitioned wall, floor and roof components with interior edges. In this regard, sealing structures can be utilized, with the objective to limit or prevent the ingress of rain water, noise and outside air across these exterior and interior edges into the interior ofstructure 150. - Particular sealing structures for accomplishing the foregoing objective are described in U.S. Non-Provisional patent application Ser. No. 17/504,883, filed on Oct. 19, 2021, entitled “Sheet/Panel Design for Enclosure Component Manufacture” and having the same inventors as the present application, and in PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as the present application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/504,883, filed on Oct. 19, 2021, entitled “Sheet/Panel Design for Enclosure Component Manufacture” and having the same inventors as the present application, are hereby incorporated by reference as if fully set forth herein, particularly including the sealing systems described for example at ¶¶0083-0170 and depicted in FIGS. 10-20 thereof, and also including the exemplary placements for such sealing systems described in ¶¶0171-0177 and depicted in
FIGS. 21A-21B thereof. The contents of that PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as the present application, are also incorporated by reference as if fully set forth herein, particularly including the sealing systems described for example at ¶¶0080-0167 and depicted inFIGS. 9-20 thereof, and also including the exemplary placements for such sealing systems described in ¶¶0168-0174 and depicted inFIGS. 8A-8B thereof. - F. Enclosure Component Load Transfer
- In the case of
enclosure components 155, it is necessary to transfer the loads imposed on their surfaces to their exterior edges, where those loads can be transferred either to or through adjoining walls, or to the building foundation. Forenclosure components 155 that are horizontally oriented when in use (floor component 300 and roof component 400), such loads include the weight of equipment, furniture and people borne by their surfaces, as well as vertical seismic loads. For enclosure components that are vertically oriented when in use (wall component 200), such loads include those arising from meteorological conditions (hurricanes, tornadoes, etc.) and human action (vehicle and other object impacts). - For this purpose, multi-layered, laminate design shown in
FIG. 4 will function to transfer the loads described above. To add additional load transfer capability, structural members, such as beams and/or joists, can be utilized within the perimeter of theenclosure components 155, as is deemed appropriate to the specific design ofstructure 150 and theparticular enclosure component 155, to assist in the transfer of loads to the exterior edges. Particular embodiments of such structural members which can be used infloor components 300 androof components 400, which also incorporate hinge structures, are described below. - G. Enclosure Component Manufacture
- It is preferred that each
enclosure component 155—that is to say, allwall components 200, allfloor components 300 and allroof components 400—be fabricated from a common subassembly, referred to herein asenclosure component workpiece 250. - An embodiment of
workpiece 250 is shown in exploded form inFIG. 5 . In this embodiment, first and second surface layers 210, 215 can be cement board, joinder splines 213, 217 can be steel strip, andreinforcement spline 221 can be lumber. - The
workpiece 250 in theFIG. 5 embodiment uses six planar rectangular first surface panels 211 forfirst surface layer 210. Four of these first surface panels 211 have the same width and length (X, Y direction respectively inFIG. 5 ), and are designated “211-1” inFIG. 5 . In the preferred embodiment, the remaining two of the six first surface panels 211, designated “211-2” inFIG. 5 , each has the same length as first surface panels 211-1, but is smaller in width than first surface panels 211-1. Each first surface panel 211-2 of theworkpiece 250 has the same length and width as the other first surface panel 211-2. Accordingly, from a manufacturing standpoint two stock keeping units, or SKUs, can be utilized to form thefirst surface layer 210 of theworkpiece 250. - The
workpiece 250 in theFIG. 5 embodiment also uses six planar rectangular second surface panels 216 forsecond surface layer 215. Four of these second surface panels 211 have the same length and width, and are designated “216-1” inFIG. 5 . In the preferred embodiment, the remaining two of the six second surface panels 216, designated “216-2” inFIG. 5 , each has the same length as first surface panels 216-1, but is smaller in width than first surface panels 216-1. Each second surface panel 216-2 of theworkpiece 250 has the same length and width as the other second surface panel 216-2. Accordingly, from a manufacturing standpoint two SKUs can be utilized to form thesecond surface layer 215 of theworkpiece 250. - In the embodiment shown in
FIG. 5 , each first surface panel 211 can be 114 inches (2.9 m) long (Y direction inFIG. 5 ), and that each second surface panel 216 also can be 114 inches (2.9 m) long. As indicated above, it is preferred that first surface panels 211 be provided in two widths (X direction inFIG. 5 ). Thus in theFIG. 5 embodiment, there can be a first width of 48 inches (1.22 m) for first surface panel 211-1, and a second width of 18 inches (0.46 m) for first surface panel 211-2. Likewise, it is preferred that second surface panels 216 also be provided in two widths. Thus in theFIG. 5 embodiment, there can be a first width of 48 inches (1.22 m) for second surface panel 216-1, and a second width of 18 inches (0.46 m) for second surface panel 216-2. First surface panels 211 and second surface panels 216 can be for example 0.3125 in (0.7938 cm) thick cement board. In the case wherefirst surface layer 210 andsecond surface layer 215 are made of the same material, then the first and second surface layers 210, 215 ofworkpiece 250 can be fabricated using but two SKUs. - The
workpiece 250 additionally uses five planar rectangular foam panels 214 forcore layer 160, each preferably having the same length (Y-direction inFIG. 5 ) as surface panels 211, 216; thus if surface panels 211, 216 are 114 inches (2.9 m) long, then foam panels preferably are 114 inches (2.9 m) long. Each of the foam panels 214 is provided with one or more elongate vertically-oriented internal passageways extending parallel to the y-axis, referred to asvertical chases 219, spanning the distance between their top and bottom edges. Vertical chases 219 facilitate the installation of utility lines. The foam panels 214 in the depicted embodiment are also provided with one or more horizontal internal passageways, referred to ashorizontal chases 207, which span the width of foam panels 214. The horizontal chases 207 extend parallel to the X-axis inFIG. 5 , perpendicular to the Y-axis, and generally in the same plane as thevertical chases 219 such that and thehorizontal chases 207 intersectvertical chases 219. Horizontal chases 207 facilitate wiring acrossenclosure component 155. Thevertical chases 219 andhorizontal chases 207 are formed in and completely surrounded by the foam of the foam panels along their lengths, except that the ends of thevertical chases 219 andhorizontal chases 207 can be accessible at one or more edges of thework piece 250 and/or thevertical chases 219 andhorizontal chases 207 can be accessed via any cutout formed in theworkpiece 250. Reference to vertical, horizontal, top and bottom with respect to theworkpiece 250 is provided to illustrate a relative relationship of the components that form theworkpiece 250 as it is illustrated inFIGS. 5 and 6 , not necessarily relative to theshipping module 15 or structure 1250. For example, as theworkpieces 250 can be utilized to form awall component 200, afloor component 300, and aroof component 400, the orientation of the workpieces will vary. - The placement of
vertical chases 219 andhorizontal chases 207 in foam panels 214 is shown in the cross-section ofcore layer 160 ofFIG. 6 taken along the X-Y axis. It is preferred thatvertical chases 219 be uniformly spaced apart a distance equal to 0.5E, which in the embodiment shown is a distance of 28.5 inches (72.4 cm). It is additionally preferred that one of thevertical chases 219, denominated 219 C inFIG. 6 , be positioned at the X-direction mid-length point of core layer 160 (seeFIG. 6 ), and that the remainingchases 219 be spaced outward 0.5E to each side of that mid-length pointvertical chase 219 C. It is further preferred that there be an even number ofhorizontal chases 207 symmetrically placed above and below the Y-direction mid-length point ofcore layer 160; in the embodiment shown inFIG. 6 , there are two suchhorizontal chases 207 incore layer 160. In the case where foam panels 214 are 114 inches (2.9 m) long (Y direction inFIG. 5 ), then the first suchhorizontal chase 207 can be positioned 16 inches (40.6 cm) above the bottom edge of core layer 160 (Y direction inFIG. 6 ), and the second suchhorizontal chase 207 can be positioned 16 inches (40.6 cm) below the top edge ofcore layer 160. The horizontal chases 207 in each of the adjacent foam panels 214 are aligned to provide a path of communication across the length (X direction inFIG. 6 ) of theworkpiece 250. - The vertical and horizontal passageways in foam panels 214 defining vertical and
horizontal chases workpiece 250. These passages can be formed for example by use of a hot wire shaped and directed to form within panels 214 a cylindrical or other desired closed shape, thereby forming a foam plug severed from the bulk foam. Removal of the foam plug yields the desired passageway defining avertical chase 219 or ahorizontal chase 207. - Each
chase vertical chase 219 in each foam panel 214-3, designated 219W inFIG. 6 , can be made larger in cross-section than the vertical chases in other locations. In the embodiment shown inFIG. 6 , the twohorizontal chases 207 shown running through the foam panels 214 each has the same area in cross-section asvertical chases 219W. Thus eachvertical chase 219W has an oval shape with a major diameter for example of approximately 5 inches (12.7 cm), and eachhorizontal chase 207 in foam panels 214-1, 214-2 and 214-3 has an oval shape with a major diameter of approximately 5 inches (12.7 cm). In comparison, each of thevertical chases 219 in foam panels 214-1 and 214-2 has a circular shape with a diameter of approximately 1.5 inches (3.8 cm). Notably, a loop pathway,utility service sub-system 460, can be traced throughvertical chases 219W andhorizontal chases 207 in the foam panels 214 (shown as a dashed line inFIG. 6 ), which sub-system is generally located about the periphery ofwork piece 250, and through which utility trunk lines can be conveniently routed and connected to service lines. - On one of the faces of the foam panels 214 for
core layer 160, there are provided at select intervals, therecesses 222 that will receive reinforcement splines 221. It is preferred that therecesses 222 be uniformly spaced apart a distance equal to E, which in the embodiment shown is a distance of 57 inches (145 cm). It is additionally preferred that the recesses 222 (and the reinforcement splines 221 therein) be symmetrically positioned to each side of the X-direction mid-point ofcore layer 160. - The X-direction mid-point of one of these foam panels 214, designated “214-1” in
FIG. 5 , is positioned to coincide with the X direction mid-point (inFIG. 5 ) of theworkpiece 250. The width of foam panel 214-1 in theFIG. 5 embodiment is 48 inches (1.22 m). Further, whenworkpiece 250 is utilized in accordance with the manufacturing sequences described below, and if theworkpiece 250 is used to fabricate: -
- (a) a
wall component 200, then foam panel 214-1 will be located at the mid-point of thewall component 200; or - (b) a
floor component 300, then foam panel 214-1 will be located at the mid-point of the floor component (in the transverse direction); or - (c) a
roof component 400, then foam panel 214-1 will be located at the mid-point of the roof component (in the transverse direction).
- (a) a
- Further, foam panel 214-1 preferably is symmetric about its “X” and “Y” axes; i.e., the
vertical chase 219 andhorizontal chases 207 in foam panel 214-1 are symmetrically located within foam panel 214-1 about the X, Y axes bisecting foam panel 214-1. In the preferred embodiment,workpiece 250 includes only one foam panel 214-1. In the embodiment shown inFIG. 5 , there is but onevertical chase 219, chase 219 C as previously noted, located at the Y axis bisecting foam panel 214-1. As may be appreciated from the foregoing, and as illustrated inFIG. 6 ,vertical chase 219 C will coincide with one of the mid-point grid lines G, the particular one (GL or GT) depending upon theenclosure component 155 in which theworkpiece 250 is used. - The foam panels 214 placed to each side of foam panel 214-1 and in contact with foam panel 214-1 are designated as foam panels 214-2 in
FIG. 5 . In the embodiment shown, each foam panel 214-2 is symmetric about its X axis, but not about its Y axis; i.e., thehorizontal chases 207 in foam panel 214-2 are symmetrically located about the X axis bisecting foam panel 214-2 (and align with thehorizontal chases 207 in foam panel 214-1), but thevertical chases 219 are not symmetrically located about the Y axis bisecting foam panel 214-2. - In the embodiment shown in
FIG. 5 , the width of foam panel 214-2 is 48 inches (1.22 m). There is a firstvertical chase 219 located in foam panel 214-2, spaced preferably 0.5 E fromvertical chase 219 C, which in the embodiment depicted is 4.5 inches (11.43 cm) from the edge of foam panel 214-2 abutting foam panel 214-1. In addition, there is a secondvertical chase 219 located in foam panel 214-2, spaced preferably E fromvertical chase 219 C, which in the embodiment depicted is thirty three inches (83.8 cm) from the edge of foam panel 214-2 abutting foam panel 214-1. Furthermore, on one face of foam panel 214-2, there is provided arecess 222, which after assembly ofwork piece 250 preferably is located a distance E from the X-direction mid-point of foam panel 214-1, which location in the embodiment depicted is 4.5 inches (11.43 cm) from the edge of foam panel 214-2 abutting foam panel 214-1. Thisrecess 222 when so positioned will overlie thevertical chase 219 located in foam panel 214-2 which is preferably spaced 0.5 E fromvertical chase 219 C, as can be seen inFIG. 6 . - In assembly, one of the foam panels 214-2 is rotated 180 degrees (180°) about its Z axis relative to the other of the foam panels 214-2, to result in the
vertical chases 219 in foam panels 214-2 to be symmetrically located about the Y axis bisecting foam panel 214-1. For this reason, one of the foam panels 214-2 inFIG. 5 is designated 214-2U, and the other is designated 214-2D, to reflect their different orientations. - The foam panels placed to each side of foam panels 214-2 in
FIG. 5 are designated foam panels 214-3. In the embodiment shown, each foam panel 214-3 is symmetric about its X axis, but not about its Y axis; i.e., thehorizontal chases 207 in foam panel 214-3 are symmetrically located about the X axis bisecting foam panel 214-3 (and align with thehorizontal chases 207 in foam panel 214-2), but thevertical chases 219 are not symmetrically located about the Y axis bisecting foam panel 214-3. - In the embodiment shown in
FIG. 5 , the width of foam panel 214-3 is 42 inches (1.07 m). There is a firstvertical chase 219 located in foam panel 214-3, spaced preferably 1.5 E fromvertical chase 219 C, which in the embodiment depicted is 13.5 inches (34.3 cm) from the edge of foam panel 214-3 abutting foam panel 214-2. In addition, there is a secondvertical chase 219 located in foam panel 214-3, spaced preferably 2E fromvertical chase 219 C, which in the embodiment depicted is at the exterior edge of foam panel 214-3; i.e., 42 inches (106.7 cm) from the edge of foam panel 214-2 abutting foam panel 214-3. Furthermore, on one face of foam panel 214-3, there is provided arecess 222, which after assembly ofwork piece 250 preferably is located a distance 1.5E from the Y direction mid-point of foam panel 214-1, which location in the embodiment depicted is 13.5 inches (34.3 cm) from the edge of foam panel 214-3 abutting foam panel 214-2. Thisrecess 222 when so positioned will overlie thevertical chase 219 located in foam panel 214-3 which is also preferably spaced 1.5 E fromvertical chase 219 C. - In assembly, one of the foam panels 214-3 is rotated 180 degrees (180°) about its Z axis (see
FIG. 5 ) relative to the other of the foam panels 214-3, to result in thevertical chases 219 in foam panels 214-3 to be symmetrically located about the Y axis bisecting foam panel 214-1. For this reason, one of the foam panels 214-3 inFIG. 5 is designated 214-3U, and the other is designated 214-3D, to reflect their different orientations. - As is evident from the foregoing, from a manufacturing standpoint five panels with three SKUs can be utilized to form the
foam layer 160 of theworkpiece 250, namely foam panels 214-1 (one panel), 214-2 (two panels) and 214-3 (two panels). If first surface panels 211 and second surface panels 216 are 0.3125 in (0.7938 cm) thick, and if the foam panels 214 are made 5.375 in (13.65 cm) thick, then workpiece 250 will have an overall thickness of 6 in (15.24 cm). -
FIG. 5 depicts a number of spaced-aparttoe screw apertures 287 in each of the four first surface panels 211-1. In the event that workpiece 250 is to be used to manufacturewall component 200, theseapertures 287 can be provided to receive toe screw housings which facilitate fastening thewall component 200 to afloor component 300. In use, a toe screw housing is inserted into atoe screw aperture 287, following which a fastener, such as a SIP screw, can be inserted and driven into the underlying exterior edge reinforcement of both thewall component 200 and theunderlying floor component 300, to fasten thewall component 200 to thefloor component 300. A detailed description of the construction of one embodiment of a toe screw housing is set forth in U.S. Non-Provisional patent application Ser. No. 17/587,051 entitled “Wall Component Appurtenances”, filed Jan. 28, 2022 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/587,051 entitled “Wall Component Appurtenances”, filed Jan. 28, 2022 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of toe screw housing 288, set forth for example in ¶¶0048-0055 and inFIGS. 8A-8C thereof.Toe screw apertures 287 need not be provided inwork pieces 250 intended for use infloor components 300 orroof components 400. - It is desirable for
toe screw apertures 287 not to overlie any of thevertical chases 219, so as to avoid a fastener being driven through for example electrical wiring running throughchases 219. In this regard, when the preferred dimensional relationships and dimensions forworkpiece 250 described above are employed, the seam between the inner two first surface panels 211-1 will overlie thechase 219 C in foam panel 214-1. Thus, by placing thefirst aperture 287 to each side of this seam a distance equal to 0.125E, or 7.125 inches (18.1 cm), and spacing apart each succeeding aperture 287 a distance equal to 0.25E, or 14.25 inches (36.2 cm), thetoe screw apertures 287 will not overlie any of the vertical chases 219. This spacing pattern fortoe screw apertures 287 is shown inFIG. 5 . Optionally, where the manufacture of aworkpiece 250 is intended for awall component 200, the cutting ofapertures 287 can be performed on individual panels 211 prior to assemblingfirst surface layer 210. - In the embodiment of
FIG. 5 , joinder splines 213, 217 can be steel strip 112 to 114 inches (2.84 to 2.90 m) in length (Y axis inFIG. 5 ), four inches (10.16 cm) in width (X axis inFIG. 5 ) and 0.024 inch (0.061 mm) thick (Z axis inFIG. 5 ). In turn, reinforcement splines 221 can be lumber 112 to 114 inches (2.84 to 2.90 m) in length (Y axis inFIG. 5 ), 3.5 inches (8.89 cm) in width (X axis inFIG. 5 ) and 1.5 inches (3.81 cm) thick (Z axis inFIG. 5 ). - The sequence for
manufacturing workpiece 250 can proceed in various ways. A first manufacturing sequence proceeds as follows: -
- (a) The
first surface layer 210 is formed by arranging six first surface panels 211 side-by-side on a first assembly table in the following positional relationships, as shown inFIG. 5 : 211-2/211-1/211-1/211-1/211-2. - (b) Five
joinder splines 213 are then placed on the five seams of these side-by-side positioned first surface panels 211. Thesplines 213 can be fastened to the first surface panels which they overlap with a suitable adhesive, such as a polyurethane based construction adhesive, or by use of mechanical fasteners, or by use of a combination thereof. In this regard, eachspline 213 is optionally provided with spaced-apartbarbs 212 extending from the plane ofspline 213 on one side thereof, which are shown inFIG. 15B . Thesebarbs 212 assist in keeping thespline 213 in place during manufacture. - (c) Preferably concurrently with formation of the
first surface layer 210,core layer 160 is formed by arranging five foam panels 214 side-by-side on a second assembly table in the following positional relationships and orientations, as shown inFIG. 5 : 214-3D/214-2D/214-1/214-2U/214-3U. - (d) A suitable adhesive, such as a polyurethane based construction adhesive, is then applied across the exposed face of
first surface layer 210, andfoam panel layer 160 is moved from the second work table as a unit and placed on that exposed, adhesive-bearing face offirst surface layer 210. Notably, thefoam panel layer 160 is oriented so that therecesses 222 cut into foam panels 214 are exposed, and not face-down againstfirst surface layer 210. - (e) Following positioning of
foam panel layer 160 onfirst surface layer 210 as described above, the assembly is moved into a press table, such as a hydraulically or pneumatically actuated press table, which causes the assembly to be pressed together to thereby bond thefirst surface layer 210 tocore layer 160. The bonded assembly is then moved out from the press table, andreinforcement splines 221 are positioned inrecesses 222 and optionally bonded therein. - (f) Preferably overlapping in time with the performance of at least some of the foregoing manufacturing steps, the
second surface layer 215 is formed by arranging six first surface panels 216 side-by-side on an assembly table (which may or may not be same as the first assembly table or the second assembly table, depending on availability) in the following positional relationships, as shown inFIG. 5 : 216-2/216-1/216-1/216-1/216-2. Fivejoinder splines 217 are then placed on the five seams of these side-by-side positioned second surface panels 216. Thesplines 217 can be fastened to the first surface panels which they overlap with a suitable adhesive, such as a polyurethane based construction adhesive, or by use of mechanical fasteners, or by use of a combination thereof. In this regard, eachspline 217 is optionally provided with spaced-apartbarbs 212 extending from the plane ofspline 217 on one side thereof, which are shown inFIG. 15B . Thesebarbs 212 assist in keeping thespline 217 in place during manufacture. - (g) Following the positioning of
reinforcement splines 221 inrecesses 222, a suitable adhesive, such as a polyurethane based construction adhesive, is applied across the exposed face ofcore layer 160, andsecond surface layer 215 is moved from the work table as a unit and placed on the exposed, adhesive-bearing face ofcore layer 160. The assembly is next moved into a press table, which causes the assembly to be pressed together to thereby bond thesecond surface layer 215 tocore layer 160. - (h) The bonded assembly is then moved out from the press table, where all edges can optionally be given a clean-up cut.
Workpiece 250 is then made available for utilization in the fabrication ofwall component 200,floor component 300, androof component 400.
- (a) The
- Alternatively, a second manufacturing sequence proceeds as follows:
-
- (a) Five
joinder splines 213 are placed on an assembly table and separated by a distance from each other to correspond to the distance between the locations where will be each of the five seams of first surface panels 211. Locating features, such as recesses or pins, can be provided on the assembly table to assist manufacturing personnel in placing the joinder splines 213 at their proper locations. - (b) A suitable adhesive, such as a polyurethane based construction adhesive, is then applied to the exposed faces of the five joinder splines 213.
- (c)
Core layer 160 is then formed by arranging five foam panels 214 side-by-side on the assembly table, overlying the fivejoinder splines 213, in the following positional relationships and orientations, as shown inFIG. 5 : 214-3D/214-2D/214-1/214-2U/214-3U. Further the foam panels 214 are oriented so that theirrecesses 222 are face-up. - (d) A suitable adhesive, such as a polyurethane based construction adhesive, is then applied across the exposed face of
core layer 160, at least at positions spaced apart to correspond the distance between the joinder splines 217, and the fivejoinder splines 217 are placed at their appropriate locations oncore layer 160, which now present a layer of adhesive. - (e) Optionally with or following the foregoing assembly step (d), a suitable adhesive, such as a polyurethane based construction adhesive, can be applied in the
recesses 222 of the exposed face ofcore layer 160, and the reinforcement splines 221 can be positioned in therecesses 222. - (f) Preferably overlapping in time with the performance of at least some of the foregoing manufacturing steps, six first surface panels 211 are arranged side-by-side on a lamination table in the following positional relationships, as shown in
FIG. 5 : 211-2/211-1/211-1/211-1/211-2. - (g) The exposed faces of first surface panels 211 are coated with a suitable adhesive, such as a polyurethane based construction adhesive, and the sub-assembly comprising
core layer 160 andsplines side having splines 213 oriented to be in contact with first surface panels 211. - (h) Following positioning of
core layer 160 on first surface panels 211 as described above, a suitable adhesive, such as a polyurethane based construction adhesive, is applied across the entire expose face ofcore layer 160, as well as the exposed faces of the fivejoinder splines 217 and reinforcement splines 221. - (i) Preferably overlapping in time with the performance of at least some of the foregoing manufacturing steps, the
second surface layer 215 is formed by arranging six first surface panels 216 side-by-side on the assembly described above, in the following positional relationships, as shown inFIG. 5 : 216-2/216-1/216-1/216-1/216-2. - (j) The assembly is moved into a press table, such as a hydraulically or pneumatically actuated press table, which causes the assembly to be pressed together to thereby bond the
first surface layer 210 tocore layer 160, and thesecond surface layer 215 tocore layer 160.
- (a) Five
- As shown in
FIG. 8 ,certain enclosure components 155, such as thefloor component 300 andceiling component 400, can include twoidentical workpieces 250 joined together along their length by an enclosure component beam assembly 525 (e.g., which can be embodied asfloor beam assembly 325 orroof beam assembly 425 described herein) such that the enclosurecomponent beam assembly 525 is positioned between the twoworkpieces 250. As described herein, theworkpiece 250 can each include thevertical chases 219 andhorizontal chases 207, wherevertical chases 219W and thehorizontal chases 207 can define theutility service sub-systems 460, one in each of theworkpieces 250. Additionally, when theworkpieces 250 are joined by the enclosurecomponent beam assembly 525, theworkpieces 250 are aligned so that thevertical chases 219W of each work piece are aligned with each other. The beam assembly can includeopenings 527 that also align with thevertical chases 219W such that the alignedvertical chases 219W on opposite sides of the beam assembly can be in communication with each other. In this configuration, thevertical chases 219W and thehorizontal chases 207 that are proximate to a periphery of the enclosure component can form a closed path or loop, utility service system 470 that extends through the twoworkpieces 250 and thebeam assembly 525. As further described herein the enclosurecomponent beam assembly 525 can be formed of multiple beams joined together by one or more hinges (e.g.,beam assemblies 325 and 425) and theworkpieces 250 can be cut along hinge lines to allow the enclosure components to move between a folded position and an unfolded position. As may be understood, utility service system 470 is generally located about the periphery of theenclosure component 155 and comprises major portions of thevertical chases 219W and major portions of thehorizontal chases 207 proximate the edges of theenclosure component 155. Utility service system 470 is a pathway through which utility trunk lines can be conveniently routed and connected to service lines, and also provides communication between the twoutility service sub-systems 460 in thework pieces 250. - Further design details of
wall component 200,floor component 300, androof component 400 are provided in the sections following, as well as the further steps to fabricate each of the foregoing using one ormore workpieces 250. - 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 opposing partitionedwall components 200, generically denominate 200 s. One of the two opposing partitionedwall components 200 s comprisesfirst wall portion 200 s-1 andsecond wall portion 200 s-2, and the other of the two opposing partitionedwall components 200 s 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 greater in length (the dimension in the transverse direction) than the length ofthird wall portion 200 s-3 by a distance approximately equal to the thickness ofwall component 200, andsecond wall portion 200 s-2 is shorter in length than the length offourth 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 s 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 s 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 . - D. Wall Component Fabrication
- Fabrication of Partitioned Wall Components
- In the
structure 150 shown inFIG. 1B , wherewall components 200 are six inches (15.2 cm) thick, the partitionedwall components 200 s are one foot smaller in length thanwall components partitioned wall component 200 s, aworkpiece 250 is subject to the following steps: -
- (1) Six inches (15.2 cm) of material are vertically cut using for example a laser or waterjet cutter from each vertical side (Y direction in
FIGS. 5 and 7 ) of theworkpiece 250. - (2) Any
door apertures 202 andwindow apertures 204 are cut inworkpiece 250 as desired, and any electrical, plumbing or otherutility access points 276 are cut inworkpiece 250 as desired, to yield aworkpiece 250 in the state shown inFIG. 7 . In addition, iftoe screw apertures 287 were not previously formed infirst surface layer 210, then they too can be cut at this point. - (3) The
workpiece 250 is cut in the vertical direction (Y direction inFIG. 7 ) at the appropriate location (in the case ofwall portions 200 s-3 and 200 s-4, along line “B” inFIG. 7 ) to yieldwall portions 200 s-1 and 200 s-2, or, as shown inFIG. 7 ,wall portions 200 s-3 and 200 s-4. - (4) Exterior and interior edge reinforcement, together with the desired sealing structures, are positioned and bonded to the interior and exterior edges of the
workpiece 250. - (5) The
workpiece 250 is painted, following which the hinge structures for joining thewall portion 200 s-1 withwall portion 200 s-2, orwall portion 200 s-3 withwall portion 200 s-4, are also added, to complete thewall component 200 s.
- (1) Six inches (15.2 cm) of material are vertically cut using for example a laser or waterjet cutter from each vertical side (Y direction in
- Fabrication of Unpartitioned Wall Components
- To make a
wall component 200P or awall component 200R, aworkpiece 250 is subject to the following steps: -
- (1) Any
door apertures 202 andwindow apertures 204 are cut inworkpiece 250 as desired, and any electrical, plumbing or other utility access points are cut inworkpiece 250 as desired. In addition, iftoe screw apertures 287 were not previously formed infirst surface layer 210, then they too can be cut at this point. - (2) Exterior edge reinforcement, together with the desired sealing structures, are positioned and bonded to the exterior edges of the
workpiece 250. - (3) The
workpiece 250 is painted, to complete structure of thewall component
- (1) Any
- Floor Component (300)
- 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 and can be fabricated using one ormore workpieces 250. 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). - 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 inFIGS. 2 and 4 , wherefloor portion 300 b is horizontally oriented and co-planar withfloor portion 300 a. - C. Hinged Vertical Load Transfer Components for Floor Component (300)
-
FIG. 9A shows afloor beam assembly 325 that can be placed withinfloor component 300 to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne byfloor component 300 to its edges.Floor beam assembly 325 includes two I-beams beam 326 a is positioned approximately in the middle offloor portion 300 a, I-beam 326 b is positioned approximately in the middle offloor portion 300 b, and each of I-beams hinge assembly 329A joins I-beam 326 a to I-beam 326 b. Thehinge assembly 329A permitsfloor beam assembly 325 to be folded to a beam folded position shown inFIG. 9B and unfolded to a beam unfolded position shown inFIG. 9A . The I-beams hinge assembly 329A can be locked whenbeam assembly 325 is in the beam unfolded position, which transformsfloor beam assembly 325 into a rigid structure that will reinforcefloor component 300 in the direction perpendicular to its axis of folding. -
Hinge assembly 329A comprises two identicalhinge assembly portions 330A partnered together to form a pivoted junction, as shown inFIGS. 9A and 9B . A detailed description of the construction ofhinge assembly 329A and itshinge assembly portions 330A is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction ofhinge assembly 329A and itshinge assembly portions 330A set forth for example in ¶¶0075-0087 and inFIGS. 9-12 and 13C-13E thereof. - In the embodiment of
floor component 300 utilized in thestructure 150 ofFIGS. 1A-5 ,floor beam assembly 325 is located at the mid-point between firsttransverse floor edge 120 and secondtransverse floor edge 118, and nohinge assemblies 329A are utilized elsewhere withinfloor component 300, such as proximate to firsttransverse floor edge 120 and secondtransverse floor edge 118. Therefore, to assist in smoothly rotatingfloor portion 300 b, there is provided adjacent first transverse floor edge 120 a first floorend hinge assembly 345A joiningfloor portions end hinge assembly 345A joiningfloor portions end hinge assemblies 345A is indicated inFIG. 10 . Floorend hinge assembly 345A comprises two identical floor end hinge portions 350A (not specified in the figures). A description of the construction of floorend hinge assembly 345A and its floor end hinge portions 350A is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of floorend hinge assembly 345A and its floor end hinge portions 350A set forth for example in ¶¶0090-0093 and inFIGS. 14A-14B thereof. - D. Floor Component Manufacture
- A
floor component 300 comprises in substantial part twoworkpieces 250 joined by afloor beam assembly 325. In fabricating afloor component 300, eachworkpiece 250 is subject to the following steps: -
- (1) Any electrical, plumbing or other utility access points are cut in
workpiece 250 as desired. - (2) The
workpiece 250 is cut in the “Y” direction (seeFIGS. 5 and 13 ) at the appropriate location (along line “C” inFIG. 13 ) to yield twoworkpiece portions FIGS. 5 and 13 ) equals the transverse dimension offloor portion 300 a, and the transverse dimension ofworkpiece portion 302 equals the transverse dimension offloor portion 300 b. - (3) Exterior and interior edge reinforcement, together with the desired sealing structures, are positioned and bonded to the interior and exterior edges of the
workpiece portions workpiece portions floor beam assembly 325 can be pre-cut at this point to conform to the profile of the beam assembly. - (4) The
workpiece portions - (5) The two
workpieces 250 are then positioned as shown inFIG. 13 , and joined to afloor beam assembly 325 to completefloor component 300.
- (1) Any electrical, plumbing or other utility access points are cut in
- Roof Component (400)
- 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 and can be fabricated using one ormore workpieces 250.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 inFIGS. 1B, 4 and 5 , the length and width ofroof component 400 approximates the length and width offloor component 300. - 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 inFIGS. 1A and 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 fully 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 . - C. Hinged Vertical Load Transfer Components for Roof Component (400)
-
FIGS. 11A and 11B shows aroof beam assembly 425 that can be placed withinroof component 400 to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne byfloor component 300 to its edges.Roof beam assembly 425 includes three I-beams hinge assembly 429B joins I-beam 426 a to I-beam 426 b. In addition, ahinge assembly 429C joins I-beam 426 b to I-beam 426 c. Thehinge assemblies roof beam assembly 425 to be folded to a beam folded position, shown inFIG. 11B , and unfolded to a beam unfolded position, shown inFIG. 11A . The I-beams hinge assemblies roof beam assembly 425 is in the beam unfolded position, which transformsroof beam assembly 425 into a rigid structure that will reinforceroof component 400 in the direction perpendicular to its axes of folding. -
Hinge assembly 429B comprises two identicalhinge assembly portions 430B partnered together to form a pivoted junction, and hingeassembly 429C comprises two identicalhinge assembly portions 430C partnered together to form a pivoted junction. A detailed description of the construction of these hinge assemblies and their hinge assembly portions is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction ofhinge assembly 429B and itshinge assembly portions 430B set forth for example in ¶¶00106-00118 and in FIGS. 16-19 and 24A thereof, and the description of the construction ofhinge assembly 429C and itshinge assembly portions 430C set forth for example in ¶¶00119-00126 and in FIGS. 20-23 and 24A-24B thereof. - In the embodiment of
roof component 400 shown in the figures,roof beam assembly 425 is located at the mid-point between firsttransverse roof edge 408 and secondtransverse roof edge 410, and nohinge assemblies roof component 400, such as proximate to firsttransverse roof edge 408 or secondtransverse roof edge 410. Therefore, to assist in smoothly rotatingroof portion 400 b relative toroof portion 400 a, there is provided adjacent first transverse roof edge 408 a first roofend hinge assembly 445B joiningroof portions end hinge assembly 445B joiningroof portions roof portion 400 c relative toroof portion 400 b, there is provided adjacent first transverse roof edge 408 a first roofend hinge assembly 445C joiningroof portions end hinge assembly 445C joiningroof portions end hinge assemblies 445B are indicated inFIG. 12 , and the locations of first and second roofend hinge assemblies 445C are indicated inFIG. 12 . - Roof
end hinge assembly 445B comprises two identical roof end hinge portions 450B, and roofend hinge assembly 445C comprises two identical roof end hinge portions 450C (roof end hinge portions 450B, 450C are not specified in the figures). A description of the construction of these roof end hinge assemblies and roof end hinge portions is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of roofend hinge assembly 445B and its roof end hinge portions 450B set forth for example in ¶¶00127-00130 and inFIGS. 25A-25B thereof, and the description of the construction of roofend hinge assembly 445C and its roof end hinge portions 450C set forth for example in ¶¶00131-00132 and inFIGS. 24B and 25D thereof. - D. Roof Component Manufacture
- A
roof component 400 comprises in substantial part twoworkpieces 250 joined by aroof beam assembly 425. In fabricating afloor component 400, eachworkpiece 250 is subject to the following steps: -
- (1) Any electrical, plumbing or other utility access points are cut in
workpiece 250 as desired. - (2) The
workpiece 250 is cut in the “Y” direction (seeFIGS. 5 and 14 ) at appropriate locations (along lines “D1”, and “D2” inFIG. 14 ) to yield threeworkpiece portions FIGS. 5 and 14 ) equals the width ofroof portion 400 a, the width ofworkpiece portion 402 equals the width ofroof portion 400 b and the width ofworkpiece portion 403 equals the width ofroof portion 400 c. - (3) Exterior and interior edge reinforcement, together with the desired sealing structures, are positioned and bonded to the interior and exterior edges of the
workpiece portions workpiece portions roof beam assembly 425 can be pre-cut at this point to conform to the profile of the beam assembly. - (4) The
workpiece portions - (5) The two
workpieces 250 are then positioned as shown inFIG. 14 , and joined to aroof beam assembly 425 to completeroof component 400.
- (1) Any electrical, plumbing or other utility access points are cut in
- Optionally,
roof beam assembly 425 can be provided with apertures as appropriate locations to permit communication between thevertical chases 219W in each of the twoworkpieces 250. As may be understood, through these apertures there runs a closed path or loop, utility service system 470, generally located about the periphery ofroof component 400 and comprising, in addition to major portions of thevertical chases 219W, major portions of thehorizontal chases 207 proximate the longitudinal and transverse edges ofroof component 400. Utility service system 470 is a pathway through which utility trunk lines can be conveniently routed and connected to service lines, and also provides communication between the twoutility service sub-systems 460 in thework pieces 250 ofroof component 400. - 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. - It is preferred that there be a specific dimensional relationship among
enclosure components 155. -
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. - Accordingly, in the preferred embodiment each of
roof 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.Wall components wall components 200 s in the preferred embodiment is approximately 4E long, less the combined thicknesses ofwall components - 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) inFIGS. 1A and 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 of axis 105 (the general location of which is shown inFIG. 3 ), 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 inFIGS. 1A and 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 (seeFIG. 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. - This disclosure should be understood to include (as illustrative and not limiting) the subject matter set forth in the following numbered clauses:
-
Clause 1. An enclosure component for a building structure, the enclosure component having -
- a length, a width and a thickness and comprising:
- a first surface layer having a first face and an opposed second face;
- a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;
- the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;
- the second and third foam panels each having (a) an internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges;
- the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;
- an elongate reinforcement spline in each recess;
- a second surface layer having a first face and an opposed second face; and
- the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer.
Clause 2. The enclosure component ofclause 1, wherein the core layer further comprises: - a planar rectangular fourth foam panel and a planar rectangular fifth foam panel, each of the fourth and fifth foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fourth and fifth foam panels being oriented along the length of the enclosure component;
- the fourth edge of the fourth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the fourth edge of the fifth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel; and
- the first and second edges of each of the fourth and fifth foam panels each has a same third linear dimension that is different from the first linear dimension.
Clause 3. The enclosure component ofclause 2, wherein the third linear dimension is less than the first linear dimension.
Clause 4. The enclosure component of eitherclause 2 orclause 3, wherein the first edges of the first, second, third fourth and fifth foam panels are in aggregate equal to the length of the enclosure component.
Clause 5. The enclosure component of any one ofclauses
Clause 6. The enclosure component ofclaim 1, wherein the second and third foam panels are each symmetrical about a dividing line extending between the third and fourth edges and are each asymmetrical about a dividing line extending between the first and second edges.
Clause 7. The enclosure component ofclaim 1, wherein the internal passage of each of the second and third foam panels extends parallel to the recess and the internal passage and recess are offset from the fourth edge by an identical distance such that the internal passage and the recess are aligned within the thickness.
Clause 8. The enclosure component ofclaim 7, wherein the second and third foam panels include a further internal passage that is parallel to the recess and offset from the fourth edge a different distance than the recess.
Clause 9. The enclosure component ofclaim 1, wherein the internal passage in the first foam panel extends between the first and second edges midway between the third and fourth edges.
Clause 10. The enclosure component ofclaim 1, wherein one of the second or third foam panels is rotated one hundred eighty degrees relative to the other about an axis extending in a direction of the thickness that is perpendicular to the length and width.
Clause 11. The enclosure of component ofclaim 1, wherein each recess is formed on the second face of the core layer.
Clause 12. An enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising: - a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component;
- a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;
- the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;
- the first and second edges of each of the first, second, third and fourth surface panels A each has a same third linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension;
- the second and third foam panels each having (a) a linear first internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges;
- the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;
- the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A;
- an elongate reinforcement spline in each recess;
- a surface layer B having a first face and an opposed second face; and
- the second face of the surface layer A being bonded to the first face of the core layer, and the first face of the surface layer B being bonded to the second face of the core layer.
Clause 13. The enclosure component of clause 12, wherein the surface layer A further comprises: - a planar rectangular fifth surface panel A and a planar rectangular sixth surface panel A, each of the fifth and sixth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fifth and sixth surface panels A being oriented along the length of the enclosure component; and
- the first and second edges of each of the fifth and sixth surface panels A each has a same fourth linear dimension that is different from the third linear dimension.
Clause 14. The enclosure component of clause 13, wherein the fourth linear dimension is less than the third linear dimension.
Clause 15. The enclosure component of either clause 13 or clause 14, wherein the first edges of the first, second, third, fourth, fifth and sixth surface panels A are in aggregate equal to the length of the enclosure component.
Clause 16. The enclosure component of any one ofclauses 12, 13, 14 or 15, wherein the third edge of the first, second, third, fourth, fifth and sixth surface panels A each equals the width of the enclosure component.
Clause 17. The enclosure component of any one ofclauses 12, 13, 14, 15 or 16, further comprising an elongate planar rectangular first joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the first joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge.
Clause 18. The enclosure component of clause 17, wherein the first joinder spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first joinder spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the first joinder spline being oriented along the length of the enclosure component, with each of the first and second edges of the first joinder spline having a linear dimension less than 50 percent of the third linear dimension.
Clause 19. The enclosure component of clause 18, wherein the first joinder spline is bonded to the first face of the core layer.
Clause 20. The enclosure component of either of clause 18 or clause 19, wherein the first and second edges of the first joinder spline have a linear dimension less than 25 percent of the third linear dimension.
Clause 21. The enclosure component of any one of clause 18, 19 or 20, wherein the first and second edges of the first joinder spline have a linear dimension less than 10 percent of the third linear dimension.
Clause 22. The enclosure component of any one of clauses 12-21, wherein the reinforcement spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the reinforcement spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the reinforcement spline being oriented along the length of the enclosure component, with each of the first and second edges of the reinforcement spline having a linear dimension less than fifty percent of the third linear dimension.
Clause 23. The enclosure component ofclause 22, wherein the reinforcement spline is bonded to the core layer.
Clause 24. The enclosure component of either ofclause 22 or clause 23, wherein the first and second edges of the reinforcement spline having a linear dimension less than 25 percent of the fourth linear dimension.
Clause 25. The enclosure component of any one ofclause
Clause 26. The enclosure component of any one of clauses 12-25, wherein the first joinder spline is steel.
Clause 27. The enclosure component of any one of clauses 12-26, wherein one or more of the surface panels A is cement board.
Clause 28. The enclosure component of any one of clauses 12-26, wherein the reinforcement spline is wooden.
Clause 29. The enclosure component of any one of clauses 12-28, wherein the surface layer B comprises: - a planar rectangular first surface panel B and a planar rectangular second surface panel B, each of which has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, with the first and second edges being oriented along the length of the enclosure component; and
- the fourth edge of the first surface panel B arranged in a side-by-side relationship with the third edge of the second surface panel B.
Clause 30. The enclosure component of any one of clauses 12-29, further comprising an elongate planar rectangular second joinder spline overlapping the fourth edge of the first surface panel B and the third edge of the second surface panel B, the second joinder spline bonded to the first surface panel B proximate to its fourth edge and bonded to the second surface panel B proximate to its third edge.
Clause 31. The enclosure component of clause 30, wherein the second joinder spline is steel.
Clause 32. The enclosure component of any one of clauses 12-31, wherein the core layer includes a linear second internal passage parallel to the first internal passage, and a linear third internal passage parallel to the first internal passage, the first, second and third internal passages forming an internal passage array, the internal passages of which are spaced apart from each other by an integer multiple of a grid distance.
Clause 33. The enclosure component of clause 32, wherein the first surface layer includes a plurality of apertures proximate to an edge of the first surface layer that is along the length of the enclosure component, and the plurality of apertures are spaced apart from each other by one-half of an integer multiple of the grid distance.
Clause 34. The enclosure component of clause 33, wherein at least two of the plurality of apertures are bounded by at least two of the internal passages of the internal passage array, and each aperture of the at least two of the plurality of apertures is spaced apart from each passage of the at least two internal passages by an integer multiple of an offset distance.
Clause 35. The enclosure component of clause 34, wherein the offset distance is one-quarter the grid distance.
Clause 36. A foldable enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising: - first and second enclosure component sub-portions, each such enclosure component sub-portion including:
- a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component;
- a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;
- the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;
- the first and second edges of each of the first, second, third and fourth surface panels A each has a same fourth linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension;
- the second and third foam panels each having an elongate recess on a surface of the panel spanning the distance between the first and second edges;
- the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;
- the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A;
- an elongate reinforcement spline in each recess;
- an elongate planar rectangular joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge;
- a second surface layer having a first face and an opposed second face; and
- the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer;
- a beam assembly comprising a first beam joined to a second beam by a first hinge assembly defining a first hinge line;
- the first enclosure component sub-portion joined to the first beam and joined to the second beam;
- the second enclosure component sub-portion joined to the first beam and joined to the second beam; and
- the first enclosure component sub-portion divided along the first hinge line and the second enclosure sub-portion divided along the first hinge line to define a first enclosure component portion joined to the first beam and a second enclosure component portion joined to the second beam.
Clause 37. The foldable enclosure component of clause 36, wherein the beam assembly further comprises a third beam joined to the second beam by a second hinge assembly defining a second hinge line; - the first enclosure component sub-portion is further joined to the third beam;
- the second enclosure component sub-portion is further joined to the third beam; and
- the first enclosure component sub-portion is further divided along the second hinge line and the second enclosure sub-portion is further divided along the second hinge line to define a third enclosure component portion joined to the third beam.
Clause 38. A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising: - fabricating a first workpiece by performing at least the following steps:
- forming a first surface layer by arranging a plurality of planar rectangular first surface panels side-by-side to form one or more first seams between a respective one or more of the plurality of first surface panels;
- placing an elongate planar first joinder spline over one of the one or more first seams to form a first sub-assembly;
- forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel;
- forming a second surface layer by arranging a plurality of planar rectangular second surface panels side-by-side to form one or more second seams between a respective one or more of the plurality of second surface panels;
- placing a second elongate planar joinder spline over one of the one or more second seams to form a second sub-assembly;
- joining the first sub-assembly to the first face of the core layer; and
- joining the second sub-assembly to the second face of the core layer;
- thereby to fabricate the first workpiece.
Clause 39. A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising: - fabricating a first workpiece by performing at least the following steps:
- placing at least two elongate planar rectangular first joinder splines spaced-apart a first select distance to form a first spline sub-assembly;
- forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel;
- joining the first spline sub-assembly to the first face of the core layer;
- placing at least two elongate planar rectangular second joinder splines spaced-apart a second select distance to form a second spline sub-assembly;
- joining the second spline sub-assembly to the second face of the core layer;
- forming a first surface layer by arranging three planar rectangular first surface panels side-by-side to provide a first middle panel flanked by a first pair of seams, where the first middle panel is dimensioned so that the first pair of seams is separated by the first select distance;
- joining the first surface layer to the first face of the core layer and the first spline sub-assembly positioned so that the first pair of seams overlie the first joinder splines;
- forming a second surface layer by arranging three planar rectangular second surface panels side-by-side to provide a second middle panel flanked by a second pair of seams, where the second middle panel is dimensioned so that the second pair of seams is separated by the second select distance; and
- joining the second surface layer to the second face of the core layer and the second spline sub-assembly positioned so that the second pair of seams overlie the second joinder splines;
- thereby to fabricate the first workpiece.
Clause 40. The method of either of clause 38 or clause 39, further comprising cutting an access point through the first surface layer to communicate with the internal passage.
Clause 41. The method of any one ofclause 38, 39 or 40, further comprising cutting a door aperture or a window aperture through the workpiece.
Clause 42. The method of any one ofclause 38, 39, 40 or 41, further comprising cutting the first workpiece parallel to the third edge of the first foam panel into two enclosure component portions.
Clause 43. The method of either of clause 38 or clause 39, further comprising: - fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece;
- providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line;
- cutting the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular second enclosure component sub-portion;
- cutting the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular third enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular fourth enclosure component sub-portion;
- joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and
- joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.
Clause 44. The method of either of clause 38 or clause 39, further comprising: - fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece;
- providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line, with a third beam having a third beam length joined to the second beam by a second hinge assembly defining a second hinge line;
- cutting in a first cutting step the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a first cut line from a planar rectangular second enclosure component sub-portion;
- cutting in a second cutting step the second enclosure component sub-portion parallel to the first cut line, and at a distance from a first cut line edge of the second enclosure component sub-portion equal to the second beam length, to form from the second enclosure component sub-portion a planar rectangular first enclosure component third sub-portion with a side having a linear dimension equal to the second beam length, separated along a second cut line from a planar rectangular fourth enclosure component sub-portion;
- cutting in a third cutting step the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular fifth enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a third cut line from a planar rectangular sixth enclosure component sub-portion;
- cutting in a fourth cutting step the sixth enclosure component sub-portion parallel to the third cut line, and at a distance from a third cut line edge of the sixth enclosure component sub-portion equal to the second beam length, to form from the sixth enclosure component sub-portion a planar rectangular enclosure component seventh sub-portion with a side having a linear dimension equal to the second beam length, separated along a fourth cut line from a planar rectangular eighth enclosure component sub-portion;
- joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and
- joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.
Clause 45. A foldable enclosure component for a building structure, the enclosure component comprising: - a floor component formed by:
- two of the enclosure components as recited in any one of clauses 1-11 or any one of clauses 12-35; and
- a first beam assembly positioned between and joined to the enclosure components of the floor component, the first beam assembly including a first beam and a second beam attached to the first beam by a first hinge to define a first hinge line along which the enclosure components are cut to define a first portion of the floor component and a second portion of the floor component pivotally joined to each other by the first hinge to allow the floor component to move between a folded position and an unfolded position; and
- a ceiling component formed by:
- two of the enclosure components as recited in any one of clauses 1-11 or any one of clauses 12-35;
- a second beam assembly positioned between and joined to the enclosure components of the ceiling component, the second beam assembly including a first beam, a second beam attached to the first beam by a first hinge to define a first hinge line, and a third beam attached to the second beam by a second hinge to define a second hinge line, the enclosure components of the ceiling component are cut to along the first and second hinge lines of the second beam assembly to define a first portion of the ceiling component, a second portion of the ceiling component pivotally joined to the first portion of the ceiling component by the first hinge, and a third portion of the ceiling component pivotally joined to the second portion of the ceiling component by the second hinge to allow the ceiling component to move between a folded position and an unfolded position.
- 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 (46)
1. An enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising:
a first surface layer having a first face and an opposed second face;
a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;
the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;
the second and third foam panels each having (a) an internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges;
the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;
an elongate reinforcement spline in each recess;
a second surface layer having a first face and an opposed second face; and
the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer.
2. The enclosure component of claim 1 , wherein the core layer further comprises:
a planar rectangular fourth foam panel and a planar rectangular fifth foam panel, each of the fourth and fifth foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fourth and fifth foam panels being oriented along the length of the enclosure component;
the fourth edge of the fourth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the fourth edge of the fifth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel; and
the first and second edges of each of the fourth and fifth foam panels each has a same third linear dimension that is different from the first linear dimension.
3. The enclosure component of claim 2 , wherein the third linear dimension is less than the first linear dimension.
4. The enclosure component of claim 2 , wherein the first edges of the first, second, third fourth and fifth foam panels are in aggregate equal to the length of the enclosure component.
5. The enclosure component of claim 1 , wherein the third edge and the fourth edge of each of the first, second and third foam panels each equals the width of the enclosure component.
6. The enclosure component of claim 1 , wherein the second and third foam panels are each symmetrical about a dividing line extending between the third and fourth edges and are each asymmetrical about a dividing line extending between the first and second edges.
7. The enclosure component of claim 1 , wherein the internal passage of each of the second and third foam panels extends parallel to the recess and the internal passage and recess are offset from the fourth edge by an identical distance such that the internal passage and the recess are aligned within the thickness.
8. The enclosure component of claim 7 , wherein the second and third foam panels include a further internal passage that is parallel to the recess and offset from the fourth edge a different distance than the recess.
9. The enclosure component of claim 1 , wherein the internal passage in the first foam panel extends between the first and second edges midway between the third and fourth edges.
10. The enclosure component of claim 1 , wherein one of the second or third foam panels is rotated one hundred eighty degrees relative to the other about an axis extending in a direction of the thickness that is perpendicular to the length and width.
11. The enclosure of component of claim 1 , wherein each recess is formed on the second face of the core layer.
12. An enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising:
a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component;
a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;
the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;
the first and second edges of each of the first, second, third and fourth surface panels A each has a same third linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension;
the second and third foam panels each having (a) a linear first internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges;
the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;
the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A;
an elongate reinforcement spline in each recess;
a surface layer B having a first face and an opposed second face; and
the second face of the surface layer A being bonded to the first face of the core layer, and the first face of the surface layer B being bonded to the second face of the core layer.
13. The enclosure component of claim 12 , wherein the surface layer A further comprises:
a planar rectangular fifth surface panel A and a planar rectangular sixth surface panel A, each of the fifth and sixth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fifth and sixth surface panels A being oriented along the length of the enclosure component; and
the first and second edges of each of the fifth and sixth surface panels A each has a same fourth linear dimension that is different from the third linear dimension.
14. The enclosure component of claim 13 , wherein the fourth linear dimension is less than the third linear dimension.
15. The enclosure component of claim 13 , wherein the first edges of the first, second, third, fourth, fifth and sixth surface panels A are in aggregate equal to the length of the enclosure component.
16. The enclosure component of claim 12 , wherein the third edge of the first, second, third, fourth, fifth and sixth surface panels A each equals the width of the enclosure component.
17. The enclosure component of claim 12 , further comprising an elongate planar rectangular first joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the first joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge.
18. The enclosure component of claim 17 , wherein the first joinder spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first joinder spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the first joinder spline being oriented along the length of the enclosure component, with each of the first and second edges of the first joinder spline having a linear dimension less than 50 percent of the third linear dimension.
19. The enclosure component of claim 18 , wherein the first joinder spline is bonded to the first face of the core layer.
20. The enclosure component of claim 18 , wherein the first and second edges of the first joinder spline have a linear dimension less than 25 percent of the third linear dimension.
21. The enclosure component of claim 18 , wherein the first and second edges of the first joinder spline have a linear dimension less than 10 percent of the third linear dimension.
22. The enclosure component of claim 12 , wherein the reinforcement spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the reinforcement spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the reinforcement spline being oriented along the length of the enclosure component, with each of the first and second edges of the reinforcement spline having a linear dimension less than fifty percent of the third linear dimension.
23. The enclosure component of claim 22 , wherein the reinforcement spline is bonded to the core layer.
24. The enclosure component of claim 22 , wherein the first and second edges of the reinforcement spline having a linear dimension less than 25 percent of the fourth linear dimension.
25. The enclosure component of claim 22 , wherein the first and second edges of the reinforcement spline having a linear dimension less than 10 percent of the fourth linear dimension.
26. The enclosure component of claim 12 , wherein the first joinder spline is steel.
27. The enclosure component of claim 12 , wherein one or more of the surface panels A is cement board.
28. The enclosure component of claim 12 , wherein the reinforcement spline is wooden.
29. The enclosure component of claim 12 , wherein the surface layer B comprises:
a planar rectangular first surface panel B and a planar rectangular second surface panel B, each of which has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, with the first and second edges being oriented along the length of the enclosure component; and
the fourth edge of the first surface panel B arranged in a side-by-side relationship with the third edge of the second surface panel B.
30. The enclosure component of claim 12 , further comprising an elongate planar rectangular second joinder spline overlapping the fourth edge of the first surface panel B and the third edge of the second surface panel B, the second joinder spline bonded to the first surface panel B proximate to its fourth edge and bonded to the second surface panel B proximate to its third edge.
31. The enclosure component of claim 30 , wherein the second joinder spline is steel.
32. The enclosure component of claim 12 , wherein the core layer includes a linear second internal passage parallel to the first internal passage, and a linear third internal passage parallel to the first internal passage, the first, second and third internal passages forming an internal passage array, the internal passages of which are spaced apart from each other by an integer multiple of a grid distance.
33. The enclosure component of claim 32 , wherein the first surface layer includes a plurality of apertures proximate to an edge of the first surface layer that is along the length of the enclosure component, and the plurality of apertures are spaced apart from each other by one-half of an integer multiple of the grid distance.
34. The enclosure component of claim 33 , wherein at least two of the plurality of apertures are bounded by at least two of the internal passages of the internal passage array, and each aperture of the at least two of the plurality of apertures is spaced apart from each passage of the at least two internal passages by an integer multiple of an offset distance.
35. The enclosure component of claim 34 , wherein the offset distance is one-quarter the grid distance.
36. A foldable enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising:
first and second enclosure component sub-portions, each such enclosure component sub-portion including:
a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component;
a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;
the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;
the first and second edges of each of the first, second, third and fourth surface panels A each has a same fourth linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension;
the second and third foam panels each having an elongate recess on a surface of the panel spanning the distance between the first and second edges;
the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;
the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A;
an elongate reinforcement spline in each recess;
an elongate planar rectangular joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge;
a second surface layer having a first face and an opposed second face; and
the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer;
a beam assembly comprising a first beam joined to a second beam by a first hinge assembly defining a first hinge line;
the first enclosure component sub-portion joined to the first beam and joined to the second beam;
the second enclosure component sub-portion joined to the first beam and joined to the second beam; and
the first enclosure component sub-portion divided along the first hinge line and the second enclosure sub-portion divided along the first hinge line to define a first enclosure component portion joined to the first beam and a second enclosure component portion joined to the second beam.
37. The foldable enclosure component of claim 36 , wherein the beam assembly further comprises a third beam joined to the second beam by a second hinge assembly defining a second hinge line;
the first enclosure component sub-portion is further joined to the third beam;
the second enclosure component sub-portion is further joined to the third beam; and
the first enclosure component sub-portion is further divided along the second hinge line and the second enclosure sub-portion is further divided along the second hinge line to define a third enclosure component portion joined to the third beam.
38. A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising:
fabricating a first workpiece by performing at least the following steps:
forming a first surface layer by arranging a plurality of planar rectangular first surface panels side-by-side to form one or more first seams between a respective one or more of the plurality of first surface panels;
placing an elongate planar first joinder spline over one of the one or more first seams to form a first sub-assembly;
forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel;
forming a second surface layer by arranging a plurality of planar rectangular second surface panels side-by-side to form one or more second seams between a respective one or more of the plurality of second surface panels;
placing a second elongate planar joinder spline over one of the one or more second seams to form a second sub-assembly;
joining the first sub-assembly to the first face of the core layer; and
joining the second sub-assembly to the second face of the core layer;
thereby to fabricate the first workpiece.
39. A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising:
fabricating a first workpiece by performing at least the following steps:
placing at least two elongate planar rectangular first joinder splines spaced-apart a first select distance to form a first spline sub-assembly;
forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel;
joining the first spline sub-assembly to the first face of the core layer;
placing at least two elongate planar rectangular second joinder splines spaced-apart a second select distance to form a second spline sub-assembly;
joining the second spline sub-assembly to the second face of the core layer;
forming a first surface layer by arranging three planar rectangular first surface panels side-by-side to provide a first middle panel flanked by a first pair of seams, where the first middle panel is dimensioned so that the first pair of seams is separated by the first select distance;
joining the first surface layer to the first face of the core layer and the first spline sub-assembly positioned so that the first pair of seams overlie the first joinder splines;
forming a second surface layer by arranging three planar rectangular second surface panels side-by-side to provide a second middle panel flanked by a second pair of seams, where the second middle panel is dimensioned so that the second pair of seams is separated by the second select distance; and
joining the second surface layer to the second face of the core layer and the second spline sub-assembly positioned so that the second pair of seams overlie the second joinder splines;
thereby to fabricate the first workpiece.
40. The method of claim 38 , further comprising cutting an access point through the first surface layer to communicate with the internal passage.
41. The method of claim 38 , further comprising cutting a door aperture or a window aperture through the workpiece.
42. The method of claim 38 , further comprising cutting the first workpiece parallel to the third edge of the first foam panel into two enclosure component portions.
43. The method of claim 38 , further comprising:
fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece;
providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line;
cutting the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular second enclosure component sub-portion;
cutting the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular third enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular fourth enclosure component sub-portion;
joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and
joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.
44. The method of claim 38 , further comprising:
fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece;
providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line, with a third beam having a third beam length joined to the second beam by a second hinge assembly defining a second hinge line;
cutting in a first cutting step the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a first cut line from a planar rectangular second enclosure component sub-portion;
cutting in a second cutting step the second enclosure component sub-portion parallel to the first cut line, and at a distance from a first cut line edge of the second enclosure component sub-portion equal to the second beam length, to form from the second enclosure component sub-portion a planar rectangular first enclosure component third sub-portion with a side having a linear dimension equal to the second beam length, separated along a second cut line from a planar rectangular fourth enclosure component sub-portion;
cutting in a third cutting step the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular fifth enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a third cut line from a planar rectangular sixth enclosure component sub-portion;
cutting in a fourth cutting step the sixth enclosure component sub-portion parallel to the third cut line, and at a distance from a third cut line edge of the sixth enclosure component sub-portion equal to the second beam length, to form from the sixth enclosure component sub-portion a planar rectangular enclosure component seventh sub-portion with a side having a linear dimension equal to the second beam length, separated along a fourth cut line from a planar rectangular eighth enclosure component sub-portion;
joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and
joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.
45. A foldable enclosure component for a building structure, the enclosure component comprising:
a floor component formed by:
two of the enclosure components as recited in claim 1 ; and
a first beam assembly positioned between and joined to the enclosure components of the floor component, the first beam assembly including a first beam and a second beam attached to the first beam by a first hinge to define a first hinge line along which the enclosure components are cut to define a first portion of the floor component and a second portion of the floor component pivotally joined to each other by the first hinge to allow the floor component to move between a folded position and an unfolded position; and
a ceiling component formed by:
two of the enclosure components as recited in claim 1 ;
a second beam assembly positioned between and joined to the enclosure components of the ceiling component, the second beam assembly including a first beam, a second beam attached to the first beam by a first hinge to define a first hinge line, and a third beam attached to the second beam by a second hinge to define a second hinge line, the enclosure components of the ceiling component are cut to along the first and second hinge lines of the second beam assembly to define a first portion of the ceiling component, a second portion of the ceiling component pivotally joined to the first portion of the ceiling component by the first hinge, and a third portion of the ceiling component pivotally joined to the second portion of the ceiling component by the second hinge to allow the ceiling component to move between a folded position and an unfolded position.
46. A foldable enclosure component for a building structure, the enclosure component comprising:
a floor component formed by:
two of the enclosure components as recited in claim 12 ; and
a first beam assembly positioned between and joined to the enclosure components of the floor component, the first beam assembly including a first beam and a second beam attached to the first beam by a first hinge to define a first hinge line along which the enclosure components are cut to define a first portion of the floor component and a second portion of the floor component pivotally joined to each other by the first hinge to allow the floor component to move between a folded position and an unfolded position; and
a ceiling component formed by:
two of the enclosure components as recited in claim 12 ;
a second beam assembly positioned between and joined to the enclosure components of the ceiling component, the second beam assembly including a first beam, a second beam attached to the first beam by a first hinge to define a first hinge line, and a third beam attached to the second beam by a second hinge to define a second hinge line, the enclosure components of the ceiling component are cut to along the first and second hinge lines of the second beam assembly to define a first portion of the ceiling component, a second portion of the ceiling component pivotally joined to the first portion of the ceiling component by the first hinge, and a third portion of the ceiling component pivotally joined to the second portion of the ceiling component by the second hinge to allow the ceiling component to move between a folded position and an unfolded position.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US18/232,884 US20240060291A1 (en) | 2022-08-19 | 2023-08-11 | Subassembly for enclosure component manufacture |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US202263399389P | 2022-08-19 | 2022-08-19 | |
US18/232,884 US20240060291A1 (en) | 2022-08-19 | 2023-08-11 | Subassembly for enclosure component manufacture |
Publications (1)
Publication Number | Publication Date |
---|---|
US20240060291A1 true US20240060291A1 (en) | 2024-02-22 |
Family
ID=89907499
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US18/232,884 Pending US20240060291A1 (en) | 2022-08-19 | 2023-08-11 | Subassembly for enclosure component manufacture |
Country Status (2)
Country | Link |
---|---|
US (1) | US20240060291A1 (en) |
WO (1) | WO2024039577A1 (en) |
Family Cites Families (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3236014A (en) * | 1961-10-02 | 1966-02-22 | Edgar Norman | Panel assembly joint |
GB1134625A (en) * | 1965-09-27 | 1968-11-27 | Ici Ltd | Building panel |
US3729889A (en) * | 1970-09-14 | 1973-05-01 | Pet Inc | Modular insulated panel system |
FR2333907A1 (en) * | 1975-12-01 | 1977-07-01 | Foyers Batiment Metaux | PREFABRICATED MODULAR BUILDING |
US4862660A (en) * | 1987-07-13 | 1989-09-05 | Raymond Harry W | Foamed panel including an internally mounted stud |
CA2298170A1 (en) * | 2000-02-11 | 2001-08-11 | Jean-Louis Beliveau | Stackable construction panel |
US6604328B1 (en) * | 2001-09-12 | 2003-08-12 | David R. Paddock | Portable cabin, components therefor, methods of making and erecting same |
CA2568610A1 (en) * | 2006-11-21 | 2008-05-21 | Bernard J. Nadon | Foam core panel for prefabricated buildings |
NZ583715A (en) * | 2007-08-10 | 2011-08-26 | Systems Australia Pty Ltd Const | Panel building system |
US8650807B2 (en) * | 2010-06-30 | 2014-02-18 | Suncast Technologies, Llc | Modular blow molded shed with connectors |
US20180112389A1 (en) * | 2015-04-14 | 2018-04-26 | Adam G. Lake | Composite concrete and foam building component |
WO2020167673A1 (en) * | 2019-02-14 | 2020-08-20 | 500 Group, Inc. | Enclosure component perimeter structures |
US20220220725A1 (en) * | 2021-01-12 | 2022-07-14 | Build Ip Llc | Folding Beam Systems |
-
2023
- 2023-08-11 US US18/232,884 patent/US20240060291A1/en active Pending
- 2023-08-11 WO PCT/US2023/030033 patent/WO2024039577A1/en unknown
Also Published As
Publication number | Publication date |
---|---|
WO2024039577A1 (en) | 2024-02-22 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11821196B2 (en) | Foldable building structures with utility channels and laminate enclosures | |
US20220220725A1 (en) | Folding Beam Systems | |
US11718984B2 (en) | Liftable foldable transportable buildings | |
US11739547B2 (en) | Stackable foldable transportable buildings | |
US20230383522A1 (en) | Foldable transportable buildings | |
US20240060291A1 (en) | Subassembly for enclosure component manufacture | |
US4067159A (en) | Building cluster of a plurality of building units | |
US20220220721A1 (en) | Enclosure Component Panel Sections | |
US20240165647A1 (en) | Planar component assembly line | |
US20240018779A1 (en) | Universal panel | |
CA3204970A1 (en) | Sheet/panel design for enclosure component manufacture | |
US20220219441A1 (en) | Enclosure Component Fabrication Facility | |
WO2022154926A1 (en) | Enclosure component fabrication facility | |
EP4278049A1 (en) | Enclosure component panel sections | |
US20220220726A1 (en) | Wall Component Appurtenances | |
CA3204932A1 (en) | Folding beam systems | |
US20220220722A1 (en) | Folding Roof Component | |
WO2022154855A1 (en) | Folding beam systems | |
CA3204974A1 (en) | Improved folding roof component | |
AU2022268186A1 (en) | Wall component appurtenances |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |