WO2016044709A1

WO2016044709A1 - Foldable building units with in-floor or on-floor underside nesting folding wall assembly, and methods of constructing buildings therefrom

Info

Publication number: WO2016044709A1
Application number: PCT/US2015/050913
Authority: WO
Inventors: Dennis Michaud
Original assignee: Blu Homes, Inc.
Priority date: 2014-09-19
Filing date: 2015-09-18
Publication date: 2016-03-24

Abstract

Prefabricated foldable building units are described that have a wall assembly designed and foldably connected such that the foldable building units can be more space efficiently(most importantly, width efficiently) folded and/or the wall assembly can be folded and unfolded without risking damage to prefabricated finished floor finishes of foldably connected floor sections adjacent to the interior wall assembly. The foldable building units in folded configuration include one or more foldably connected floor and wall sections that are stacked between a core structure and an interior wall assembly. This allows building units in which the interior wall assembly is width efficiently stored within a floor cavity during transport. Further, methods for constructing a building from the foldable building units are described.

Description

FOLD ABLE BUILDING UNITS WITH IN-FLOOR OR ON-FLOOR UNDERSIDE NESTING FOLDING WALL ASSEMBLY, AND METHODS OF

CONSTRUCTING BUILDINGS THEREFROM

RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Application No. 62/052,683, filed on September 19, 2014. The entire teachings of the above application(s) are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Foldable building units having foldable interior walls have previously been described. However, these interior walls which generally are much narrower than the length of the foldable building unit typically add an entire folding layer to the overall thickness of the folded building unit, which makes it very difficult to space efficiently fold these foldable building units such that the folded units comply with applicable width restrictions for truck transport. Such interior walls also limit the overall design flexibility and/or available floor area of the unfolded building unit. Additionally, these interior walls fold and unfold over floor surface. Thus, it can be difficult to ensure that finished interior floor finishes are not damaged during folding and unfolding of the interior wall.

There is, therefore, a need for foldable building units having an interior wall assembly designed and foldably connected such that the foldable building units can be more efficiently (most importantly, width efficiently) folded and/or the interior wall assembly can be folded and unfolded without risking damage to any prefabricated finished floor finishes.

SUMMARY OF THE INVENTION

One embodiment of the present invention is a foldable building unit. The foldable building unit comprising (a) a core structure comprising a fixed floor and a plurality of wall sections in fixed connection with the fixed floor; (b) a floor section foldably connected, on a first side of the core structure, to the fixed floor of the core structure; and (c) a wall assembly foldably connected to the core structure on the first side of the core structure around a vertical axis; wherein, in completely folded configuration of the foldable building unit, the foldably connected fioor section is folded between the core structure and the wall assembly..

Another embodiment of the present invention is a method for constructing a building. The method comprises (1) placing a foldable building unit as described in herein on a foundation; (2) ratably unfolding, around a vertical rotational axis, the wall assembly connected to the core structure from a folded configuration of the wall assembly, in which the foldably connected floor section is folded between the core structure and the wall assembly, to an unfolded configuration of the wall assembly, in which the foldably connected fioor section is no longer hindered by the wall assembly to ratably unfold around a first horizontal axis; and (3) ratably unfolding, around the first horizontal axis, the foldably connected floor section from a folded configuration, in which the first floor section is in a vertical position, to an unfolded configuration, in which the first floor section is in a horizontal position.

Yet another embodiment of the present invention is a building comprising a plurality of foldable building units as described herein.

The foldable building units with an interior wall assembly of the present invention have a number of advantages including that they can be space-efficiently folded, allow increased design flexibility, particularly, with regard to interior walls, and/or the interior wall assembly can be folded and unfolded without risking damage to any finished floor finishes.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention. FIG. 1 A provides an isometric schematic view of a first exemplary foldable building unit of the present invention, in completely folded configuration , having an interior wall section folded side-by-side with the underside of a floor section.

FIG. IB provides a front view of the foldable building unit of FIG. 1A. FIG. 1C provides a right side view of the foldable building unit of FIG. 1A.

FIG. ID provides a left side view of the foldable building unit of FIG. 1A. FIG. IE provides a top view of the foldable building unit of FIG. 1A.

FIG. 2 A provides an isometric schematic view of the first exemplary foldable building unit of in which the interior wall section has been unfolded into final, unfolded position.

FIG. 2B provides a front view of the foldable building unit of FIG. 2A. FIG. 2C provides a right side view of the foldable building unit of FIG. 2A. FIG. 2D provides a left side view of the foldable building unit of FIG. 2A. FIG. 2E provides a top view of the foldable building unit of FIG. 2A.

FIG. 3 A provides an isometric schematic view of the first exemplary foldable building unit in which the interior wall section and an adjacent floor section have been unfolded into final, unfolded position.

FIG. 3B provides a front view of the foldable building unit of FIG. 3 A. FIG. 3C provides a right side view of the foldable building unit of FIG. 3 A. FIG. 3D provides a left side view of the foldable building unit of FIG. 3 A.

FIG. 3E provides a top view of the foldable building unit of FIG. 3 A.

FIG. 4 A provides an isometric schematic view of the first exemplary foldable building unit in which the interior wall section and floor sections on both sides adjacent to the interior wall section have been unfolded into final, unfolded position.

FIG. 4B provides a front view of the foldable building unit of FIG. 4A. FIG. 4C provides a right side view of the foldable building unit of FIG. 4A. FIG. 4D provides a left side view of the foldable building unit of FIG. 4A. FIG. 4E provides a top view of the foldable building unit of FIG. 4A.

FIG. 5 A provides an isometric schematic view of the first exemplary foldable building unit in which the interior wall section, floor sections on both sides adjacent to the interior wall section, and an optional wall section have been unfolded into final, unfolded position.

FIG. 5B provides a front view of the foldable building unit of FIG. 5 A.

FIG. 5C provides a right side view of the foldable building unit of FIG. 5 A.

FIG. 5D provides a left side view of the foldable building unit of FIG. 5 A.

FIG. 5E provides a top view of the foldable building unit of FIG. 5 A.

FIG. 6 A provides an isometric schematic view of the first exemplary foldable building unit in which the interior wall section, floor sections on both sides adjacent to the interior wall section, and both optional wall sections have been unfolded into final, unfolded position.

FIG. 6B provides a front view of the foldable building unit of FIG. 6A.

FIG. 6C provides a right side view of the foldable building unit of FIG. 6A.

FIG. 6D provides a left side view of the foldable building unit of FIG. 6A.

FIG. 6E provides a top view of the foldable building unit of FIG. 6A.

FIG. 7 A provides an isometric schematic view of a second exemplary foldable building unit of the present invention, in completely folded configuration , having an interior wall section folded inside a cavity on the underside of a floor section.

FIG. 7B provides a front view of the foldable building unit of FIG. 7A.

FIG. 7C provides a right side view of the foldable building unit of FIG. 7A.

FIG. 7D provides a left side view of the foldable building unit of FIG. 7A.

FIG. 7E provides a top view of the foldable building unit of FIG. 7A.

FIG. 8 A provides an isometric schematic view of the second exemplary foldable building unit of in which the interior wall section has been unfolded into final, unfolded position.

FIG. 8B provides a front view of the foldable building unit of FIG. 8A.

FIG. 8C provides a right side view of the foldable building unit of FIG. 8A.

FIG. 8D provides a left side view of the foldable building unit of FIG. 8A.

FIG. 8E provides a top view of the foldable building unit of FIG. 8A.

FIG. 9 A provides an isometric schematic view of the second exemplary foldable building unit in which the interior wall section and an adjacent floor section have been unfolded into final, unfolded position. FIG. 9B provides a front view of the foldable building unit of FIG. 9A.

FIG. 9C provides a right side view of the foldable building unit of FIG. 9A.

FIG. 9D provides a left side view of the foldable building unit of FIG. 9A.

FIG. 9E provides a top view of the foldable building unit of FIG. 9A.

FIG. 10A provides an isometric schematic view of the second exemplary foldable building unit in which the interior wall section and floor sections on both sides adjacent to the interior wall section have been unfolded into final, unfolded position.

FIG. 10B provides a front view of the foldable building unit of FIG. 10A. FIG. IOC provides a right side view of the foldable building unit of FIG.

10A.

FIG. 10D provides a left side view of the foldable building unit of FIG. 10A.

FIG. 10E provides a top view of the foldable building unit of FIG. 10A.

FIG. 11 A provides an isometric schematic view of the second exemplary foldable building unit in which the interior wall section, floor sections on both sides adjacent to the interior wall section, and an optional wall section have been unfolded into final, unfolded position.

FIG. 1 IB provides a front view of the foldable building unit of FIG. 11A.

FIG. l lC provides a right side view of the foldable building unit of FIG.

11 A.

FIG. 1 ID provides a left side view of the foldable building unit of FIG. 11A.

FIG. 1 IE provides a top view of the foldable building unit of FIG. 11A.

FIG. 12A provides an isometric schematic view of the second exemplary foldable building unit in which the interior wall section, floor sections on both sides adjacent to the interior wall section, and two optional wall sections have been unfolded into final, unfolded position.

FIG. 12B provides a front view of the foldable building unit of FIG. 12A.

FIG. 12C provides a right side view of the foldable building unit of FIG.

12 A.

FIG. 12D provides a left side view of the foldable building unit of FIG. 12A. FIG. 12E provides a top view of the foldable building unit of FIG. 12A. FIG. 13 provides an isometric schematic view of a third exemplary foldable building unit of the present invention, in completely folded configuration, having an interior wall section that folds into a cavity provided on the underside of two floor sections foldably connected to the core structure, and having two foldably connected floor sections on either side of the interior wall.

FIG. 14 provides an isometric schematic view of the third examplary foldable building unit in which the interior wall section has been unfolded into final, unfolded position.

FIG. 15 provides an isometric schematic view of the third exemplary foldable building unit in which the interior wall section and a first adjacent floor section have been unfolded into final, unfolded position.

FIG. 16 provides an isometric schematic view of the third exemplary foldable building unit in which the interior wall section, a first adjacent floor section, and a second floor section, adjacent and parallel to the first floor section, have been unfolded into final, unfolded position.

FIG. 17 provides an isometric schematic view of the third exemplary foldable building unit in which the interior wall section, a first adjacent floor section, a second floor section, adjacent and parallel to the first floor section, and an optional wall section foldably connected to the second floor section have been unfolded into final, unfolded position.

FIG. 18 provides an isometric schematic view of the third exemplary foldable building unit in which the interior wall section, a first adjacent floor section, a second floor section, adjacent and parallel to the first floor section, an optional wall section foldably connected to the second floor section, and an optional wall section foldably connected to the first floor section have been unfolded into final, unfolded position.

FIG. 19 provides an isometric schematic view of the third exemplary foldable building unit in which the interior wall section, a first floor section adjacent to the interior wall section, a second floor section, adjacent and parallel to the first floor section, a third floor section adjacent to the interior wall section, an optional wall section foldably connected to the second floor section, and an optional wall section foldably connected to the first floor section have been unfolded into final, unfolded position.

FIG. 20 provides an isometric schematic view of the third exemplary foldable building unit in which the interior wall section, a first floor section adjacent to the interior wall section, a second floor section, adjacent and parallel to the first floor section, a third floor section adjacent to the interior wall section, a fourth floor section, adjacent and parallel to the third floor section, an optional wall section foldably connected to the second floor section, and an optional wall section foldably connected to the first floor section have been unfolded into final, unfolded position.

FIG. 21 provides an isometric schematic view of the third exemplary foldable building unit in which the interior wall section, a first floor section adjacent to the interior wall section, a second floor section, adjacent and parallel to the first floor section, a third floor section adjacent to the interior wall section, a fourth floor section, adjacent and parallel to the third floor section, an optional wall section foldably connected to the second floor section, an optional wall section foldably connected to the first floor section, and an optional wall section foldably connected to the third floor section have been unfolded into final, unfolded position.

FIG. 22 provides an isometric schematic view of the third exemplary foldable building unit in which the interior wall section, a first floor section adjacent to the interior wall section, a second floor section, adjacent and parallel to the first floor section, a third floor section adjacent to the interior wall section, a fourth floor section, adjacent and parallel to the third floor section, an optional wall section foldably connected to the second floor section, an optional wall section foldably connected to the first floor section, an optional wall section foldably connected to the third floor section, an optional wall section foldably connected to the fourth floor section have been unfolded into final, unfolded position, such that the four foldably connected wall sections and the short side of the interior wall section form an exterior wall.

FIG. 23 provides an isometric schematic view of a fourth exemplary foldable building unit of the present invention, in completely folded configuration, having an interior wall assembly comprised of two foldably connected wall sections folded inside a cavity on the underside of a floor section. FIG. 24 provides an isometric schematic view of the fourth exemplary foldable building unit of in which the interior wall assembly has been removed from the cavity.

FIG. 25 provides an isometric schematic view of the fourth exemplary foldable building unit of in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position.

FIG. 26 provides an isometric schematic view of the fourth exemplary foldable building unit in which the interior wall assembly and an adjacent floor section have been unfolded into final, unfolded position.

FIG. 27 provides an isometric schematic view of the fourth exemplary foldable building unit in which the interior wall assembly and floor sections on both sides adjacent to the interior wall section have been unfolded into final, unfolded position.

FIG. 28 provides an isometric schematic view of the fourth exemplary foldable building unit in which the interior wall assembly, floor sections on both sides adjacent to the interior wall section, and an optional wall section have been unfolded into final, unfolded position.

FIG. 29 provides an isometric schematic view of the fourth exemplary foldable building unit in completely unfolded configuration, in which the interior wall assembly, floor sections on both sides adjacent to the interior wall section, and two optional wall sections, each foldably connected to the floor sections, have been unfolded into final, unfolded position, thereby jointly forming an exterior wall. FIG. 30 provides an isometric schematic view of a fifth exemplary foldable building unit of the present invention, in completely folded configuration, having an interior wall section that is not connected to an fixed wall of the unit's core structure and folded inside a cavity on the underside of a floor section.

FIG. 31 provides an isometric schematic view of the fifth exemplary foldable building unit in which the interior wall section has been removed from the cavity and placed into final position. FIG. 32 provides an isometric schematic view of the fifth exemplary foldable building unit in which the interior wall section and an adjacent floor section have been unfolded into final, unfolded position.

FIG. 33 provides an isometric schematic view of the fifth exemplary foldable building unit in which the interior wall section and floor sections on both sides adjacent to the interior wall section have been unfolded into final, unfolded position.

FIG. 34 provides an isometric schematic view of the fifth exemplary foldable building unit in which the interior wall section, floor sections on both sides adjacent to the interior wall section, and an optional wall section have been unfolded into final, unfolded position.

FIG. 35 provides an isometric schematic view of the fifth exemplary foldable building unit in completely unfolded configuration, in which the interior wall section, floor sections on both sides adjacent to the interior wall section, and two optional wall sections, each foldably connected to the floor sections, have been unfolded into final, unfolded position, thereby jointly forming an exterior wall.

FIG. 36 provides an isometric schematic view of a sixth exemplary foldable building unit of the present invention, in completely folded configuration of the foldable building unit, having an interior wall section foldably connected to the core structure and nested partly within a cavity provided on the underside of a floor section, the cavity being larger than required to accommodate the interior wall section in length directon of the core structure.

FIG. 37 provides an isometric schematic view of a seventh exemplary foldable building unit of the present invention, in completely folded configuration of the foldable building unit, having an interior wall section foldably connected to the core structure and nested partly within a cavity provided on the underside of a floor section, the interior wall section extending throughout and beyond the provided cavity.

FIG. 38 provides an isometric schematic view of an eighth exemplary foldable building unit of the present invention, in completely folded configuration of the foldable building unit, having an interior wall section foldably connected to the core structure and nested partly, but with its entire thickness within a cavity provided on the underside of a floor section, the depth of the the interior wall section being less than the depth of the cavity.

FIG. 39 provides an isometric schematic view of a ninth exemplary foldable building unit of the present invention, in completely folded configuration of the foldable building unit, having an interior wall section foldably connected to the core structure and nested partly, including with regard to its thickness within a cavity provided on the underside of a floor section, the depth of the the interior wall section being greater than the depth of the cavity.

FIG. 40 provides an isometric schematic view of a tenth exemplary foldable building unit of the present invention, in completely folded configuration of the foldable building unit, having an interior wall section foldably connected to the core structure and nested completely within a cavity provided on the underside of a floor section.

FIG. 41 provides an isometric schematic view of an eleventh exemplary foldable building unit of the present invention, in completely folded configuration, having four foldably connected floor sections, two on each side of an interior wall assembly comprised of two foldably connected interior wall sections and nested within a cavity provided on the underside of one floor section.

FIG. 42 provides an isometric schematic view of the eleventh exemplary foldable building unit in which the interior wall sections are partly unfolded.

FIG. 43 provides an isometric schematic view of the eleventh exemplary foldable building unit in which the interior wall sections have been fully unfolded such that adjacent floor sections (which are foldably connected to the core structure) can be unfolded into final position.

FIG. 44 provides an isometric schematic view of the eleventh exemplary foldable building unit in which the interior wall sections have been fully unfolded, a first adjacent floor section, and a second adjacent floor section (on the other side of the interior wall, have been unfolded into final position.

FIG. 45 provides an isometric schematic view of the eleventh exemplary foldable building unit in which the interior wall sections have been fully unfolded, a first adjacent floor section, a second adjacent floor section (on the other side of the interior wall, and a third adjacent floor section foldably connected to the first floor section, have been unfolded into final position.

FIG. 46 provides an isometric schematic view of the eleventh exemplary foldable building unit in which the interior wall sections have been fully unfolded, a first adjacent floor section, a second adjacent floor section (on the other side of the interior wall, a third adjacent floor section foldably connected to the first floor section, and a fourth adjacent floor section foldably connected to the second floor section, have been unfolded into final position.

FIG. 47 provides an isometric schematic view of the eleventh exemplary foldable building unit in which the interior wall sections have been fully unfolded, a first adjacent floor section, a second adjacent floor section (on the other side of the interior wall, a third adjacent floor section foldably connected to the first floor section, a fourth adjacent floor section foldably connected to the second floor section, and a first optional wall section foldably connected to the third floor section, have been unfolded into final position.

FIG. 48 provides an isometric schematic view of the eleventh exemplary foldable building unit in which the interior wall sections have been fully unfolded, a first adjacent floor section, a second adjacent floor section (on the other side of the interior wall, a third adjacent floor section foldably connected to the first floor section, a fourth adjacent floor section foldably connected to the second floor section, a first optional wall section foldably connected to the third floor section, and a second optional wall section foldably connected to the fourth floor section have been unfolded into final position, the two optional wall sections forming one exterior wall.

FIG. 49 provides an isometric schematic view of a twelfth exemplary foldable building unit of the present invention, in completely folded configuration, having an interior wall assembly comprised of three foldably connected wall sections folded inside a cavity on the underside of a floor section.

FIG. 50 provides an isometric schematic view of the twelfth exemplary foldable building unit of in which the interior wall assembly has been removed from the cavity and is partly unfolded. FIG. 51 provides an isometric schematic view of the twelfth exemplary foldable building unit of in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position.

FIG. 52 provides an isometric schematic view of the twelfth exemplary foldable building unit in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position, and an adjacent floor section has been unfolded into final, unfolded position.

FIG. 53 provides an isometric schematic view of the twelfth exemplary foldable building unit in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position, and floor sections on both sides adjacent to the interior wall sections have been unfolded into final, unfolded position.

FIG. 54 provides an isometric schematic view of the twelfth exemplary foldable building unit in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position, and floor sections on both sides adjacent to the interior wall sections, and a first optional foldably connected wall section has been unfolded into final, unfolded position.

FIG. 55 provides an isometric schematic view of the twelfth exemplary foldable building unit in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position, floor sections on both sides adjacent to the interior wall sections, a first optional foldably connected wall section and a second optional foldably connected wall section have been unfolded into final, unfolded position.

FIG. 56 provides an isometric schematic view of the twelfth exemplary foldable building unit in which the floor sections on both sides adjacent to the interior wall sections, a first optional foldably connected wall section and a second optional foldably connected wall section have been unfolded into final, unfolded position, and the interior wall assembly has been removed from inbetween the optional wall sections and positioned over the floor. FIG. 57 provides an isometric schematic view of the twelfth exemplary foldable building unit in which the floor sections on both sides adjacent to the interior wall sections, a first optional foldably connected wall section and a second optional foldably connected wall section have been unfolded into final, unfolded position, and the interior wall assembly has been removed from inbetween the optional wall sections and unfolded into final position.

FIG. 58 provides an isometric schematic view of the twelfth exemplary foldable building unit in which the floor sections on both sides adjacent to the interior wall sections, a first optional foldably connected wall section and a second optional foldably connected wall section have been unfolded into final, unfolded position, and the interior wall assembly has been removed from inbetween the optional wall sections and unfolded into final position, and blocking has been installed between the optional wall sections, the wall sections and blocking forming one continuous wall.

FIG. 59 provides an isometric schematic view of a 13^th exemplary foldable building unit of the present invention, in completely folded configuration, having an interior wall assembly comprised of three foldably connected wall sections folded in planar arrangement inside a cavity on the underside of a floor section.

FIG. 60 provides an isometric schematic view of the 13^th exemplary foldable building unit of in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position.

FIG. 61 provides an isometric schematic view of the 13^th exemplary foldable building unit in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position, and an adjacent floor section has been unfolded into final, unfolded position.

FIG. 62 provides an isometric schematic view of the 13^th exemplary foldable building unit in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position, and floor sections on both sides adjacent to the interior wall sections have been unfolded into final, unfolded position. FIG. 63 provides an isometric schematic view of the 13 exemplary foldable building unit in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position, and floor sections on both sides adjacent to the interior wall sections, and a first optional foldably connected wall section has been unfolded into final, unfolded position.

FIG. 64 provides an isometric schematic view of the 13^th exemplary foldable building unit in which the interior wall assembly has been removed from the cavity and unfolded such that adjacent floor sections can be unfolded into final, unfolded position, floor sections on both sides adjacent to the interior wall sections, a first optional foldably connected wall section and a second optional foldably connected wall section have been unfolded into final, unfolded position.

FIG. 65 provides an isometric schematic view of the 13^th exemplary foldable building unit in which the floor sections on both sides adjacent to the interior wall sections, a first optional foldably connected wall section and a second optional foldably connected wall section have been unfolded into final, unfolded position, and the interior wall assembly has been removed from inbetween the optional wall sections and positioned over the floor.

FIG. 66 provides an isometric schematic view of the 13^th exemplary foldable building unit in which the floor sections on both sides adjacent to the interior wall sections, a first optional foldably connected wall section and a second optional foldably connected wall section have been unfolded into final, unfolded position, and the interior wall assembly has been removed from inbetween the optional wall sections and unfolded into final position.

FIG. 67 provides an isometric schematic view of the 13^th exemplary foldable building unit in which the floor sections on both sides adjacent to the interior wall sections, a first optional foldably connected wall section and a second optional foldably connected wall section have been unfolded into final, unfolded position, and the interior wall assembly has been removed from inbetween the optional wall sections and unfolded into final position, and blocking has been installed between the optional wall sections, the wall sections and blocking forming one continuous wall. DETAILED DESCRIPTION OF THE INVENTION

A description of example embodiments of the invention follows.

Although the teachings of the present invention are applicable to a wide variety of structures of different weight, size, shape and materials for a variety of diverse uses, for purposes of the following description, the present invention will be described in the context of prefabricated foldable building units.

The foldable building units of the present invention comprise at least one wall assembly which can be an interior wall assembly (i.e., a wall assembly which forms (i) an interior wall in the completely unfolded building unit, or (ii) an interior wall in the building comprising the unfolded building unit) or an exterior wall assembly (i.e., a wall assembly which is typically positioned close to or at an end of the core structure (with regard to the length of the core structure) which is foldably connected to a core structure of the foldable building unit. The wall assembly as well as other foldably connected wall and/or floor sections are designed

(dimensioned, connected, and positioned) such that, in completely folded configuration of the foldable building unit, at least one foldably connected floor sections (foldably connected with the core structure) is folded between the core structure and the wall assembly. Firstly, particularly when the wall assembly, in completely folded configuration of the foldable building unit, is at least partially, in depth or thickness direction of the interior wall assembly, positioned within a cavity provided by one or more floor sections, the foldable building units of the present invention allow efficient folding of the foldable building module in the width direction, which is particularly important because the width dimension has been found to be more limiting to practical, transportable building designs than the length or height dimension. Secondly, the foldable building units of the present invention allow folding and unfolding sequences that do not require that interior walls be moved over finished floor surfaces. This is particularly important because, in particular within the art of prefabricated building, it is desirable to achieve a high degree of finishing in the prefabrication process to significantly decrease costly on- site construction. A first embodiment of a foldable building unit of the present invention, and a respective exemplary unfolding/folding sequence of the foldable building unit, is illustrated in FIGS. 1 to 6. For ease of illustration, the figures to do not show the foldable connections (e.g., hinges) which facilitate the folding and unfolding of wall and floor sections as described in the following. FIG. 1 A provides an isometric schematic view of a foldable building unit 100 in completely folded configuration. FIGS. IB to IE provide front view, right side view, top view and left side view of the foldable building unit 100 in completely folded configuration, respectively. The foldable building unit 100 has two foldably connected floor sections 105 and 110. Each of the floor sections 105 and 110 is: (1) able to be rotated around a horizontal axis which is itself parallel to the length direction of the core structure, and (2) connected to the core structure 115, specifically, to a fixed floor 120 of the core structure. The floor sections 105 and 110 are further and optionally foldably connected, on the ends opposite to the foldable connection to the fixed floor 120, to optional wall sections 125 and 130, respectively. In this embodiment as well as in the following embodiments, the foldably connected wall sections are optional.

Instead of being foldably connected to the foldably connected floor sections they can be, for example, panelized and not hinged, or they can be site -built. Specifically, the optional foldably connected wall sections 125 and 130 are optionally ratably connected around a further horizontal axis which is itself also parallel to the length direction of the core structure 115An interior wall assembly, here one interior wall section 135, is foldably connected to an optional interior core wall section 140 of the core structure 115. (Another embodiment is described below which does not required the interior core wall section.) In the completely folded configuration of the foldable building unit 100, the foldably connected floor section 110 and the optional foldably connected wall section 130 are both folded between the core structure 115 and the interior wall section 135, with the interior wall section 135 being positioned side by side (i.e., not within a cavity provided by one or more foldably connected floor sections) with the foldably connected floor section 110.

The foldable building modules of the present invention allow the unfolding of the interior wall assembly, for example, the interior wall section 135 of foldable building module 100 of FIGS. 1A to E, to occur prior to the unfolding of adjacent foldably connected floor sections, e.g., floor sections 105 and 110. This in turn allows the prefabrication of these floor sections, for example, floor sections 105 and 110, with finished top (interior-facing) surfaces while not requiring substantial clearance between the bottom sides of the interior wall assembly, for example, bottom side of the interior wall section 135 and the finished floor surfaces. It has been found that conventional foldable building modules that have a foldable connected interior wall section which is rotated (either folded or unfolded) over flooring, require (1) leaving the floor unfinished until after the interior wall section is in its final, unfolded position, (2) leaving substantial clearance between the bottom side of the interior wall section and finished floor surface, or (3) increasing the structural strength and rigidity of the interior wall section, the connected core structure, and, particularly, the foldable connection to a materially inefficient and thereafter unnecessary (and often costly) degree. For example, it has been found that the size of metal hinges enabling the foldable connection would need to be increased to an extent that would make it difficult to leave the metal hinges in the finished building and, regardless of whether they would be removed or left in place, would require significant increase of costly on-site finishing work. It has further been found that protecting the floor finishing with protective material (e.g., sheets of polymer, advanced tribological materials such as Teflon™, rigid foam insulation, and fabrics of various composition) does not significantly reduce the risk of damage to the finished floor surface in the absence of increasing the aforementioned clearance, increasing the size of the metal hinges, and/or otherwise unnecessarily increasing the structural rigidity of the core structure and/or foldable wall assembly. Foldable building modules of the present invention having interior wall assemblies which unfold into a straight interior wall overcome this problem by allowing the interior wall assembly to be moved into final, unfolded positioned before floor sections that can have finished top surfaces are moved into final, unfolded position.

Thus, typically, the wall assembly is the first to be moved from the folded position to a position which allows adjacent floor sections to be unfolded. However, any floor sections that are not folded between the core structure and the wall assembly, can also be unfolded before the wall assembly is moved out of its folded configuration. For example, with regard to the foldable building module 100 as shown in FIGS. 1-6, foldably connected floor section 105 can be unfolded before interior wall section 135 is moved out of its folded, side by side position with floor section 110.

FIG. 2 A provides an isometric schematic view of the foldable building unit 100 in which the interior wall section 135 has been unfolded into final, unfolded position. FIGS. 2B to 2E provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 100.

FIG. 3 A provides an isometric schematic view of the foldable building unit 100 in which the interior wall section 135 and the floor section 110 have been unfolded into final, unfolded position. As the wall section 130 is foldably connected with floor section 110 at the top (with reference to the completely folded

configuration) of the floor section 110, unfolding the floor section 110 from folded to unfolded position also moves wall section 130. FIGS. 3B to 3E provide respective front view, right side view, top view and left side view of this

configuration of the foldable building unit 100. The foldable building unit 100 has a core structure 115 which includes an optional fixed wall section 145 which itself, in completely folded configuration of the foldable building unit 100, is side-by-side with wall section 130. The fixed wall section 145 is optional, that is, other foldable building modules can be identical to foldable building module 100 but do not have the fixed wall section 145. The fixed wall section 145 separates the core area from the area provided by the unfolded sections thereby forming rooms in the unfolded foldable building unit.

FIG. 4 A provides an isometric schematic view of the foldable building unit 100 in which the interior wall section 135, the floor section 110, and the floor section 105 have been unfolded into final, unfolded position. As the wall section 125 is foldably connected with floor section 105 at the top (with reference to the completely folded configuration) of the floor section 105, unfolding the floor section 105 from folded to unfolded position also moves wall section 125. FIGS. 4B to 4E provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 100. The foldable building unit 100 has a core structure 115 which includes a fixed wall section 150 which, in completely folded configuration of the foldable building unit 100, is side-by-side with optional wall section 125. The fixed wall section 150 is however optional, that is, other foldable building modules can be identical to foldable building module 100 but do not have the fixed wall section 150. Also, fixed wall section 150 and fixed wall section 145 can be combined to be a single wall section. The fixed wall section 150 separates the core area from the area provided by the unfolded sections and provides an opening between the core area and the area provided by the unfolded sections.

When folding or unfolding the foldable building units of the present invention, typically, some wall and floor sections can be unfolded in different order, leading to different folding and unfolding sequences. For example, after unfolding the floor section 110 (see FIGS. 3 A to 3E) floor section 105 can be unfolded leading to the configuration illustrated in FIGS. 4 A to 4E. Alternatively, optional wall section 130 could be unfolded into final position before floor section 105 is unfolded into final position.

FIG. 5 A provides an isometric schematic view of the foldable building unit 100 in which the interior wall section 135, the floor section 110, the floor section 105, and optional wall section 130 have been unfolded into final, unfolded position. FIGS. 5B to 5E provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 100.

FIG. 6 A provides an isometric schematic view of the foldable building unit 100 in which the interior wall section 135, the floor section 110, the floor section 105, and both optional wall sections 125 and 130 have been unfolded into final, unfolded position. FIGS. 5B to 5E provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 100.

The foldable building units of the present invention have a wall assembly foldably connected to a core structure. The wall assembly, in completely folded configuration of the foldable building unit, can (i) be positioned partially or completely within a cavity provided by one or more foldably connected floor sections, or (ii) be positioned side-by-side (vertically, and typically, parallel) with one or more foldably connected floor sections. The foldable building unit as illustrated in FIGS. 1 to 6, has an interior wall assembly, specifically, an interior wall section 135 which is in a side-by-side arrangement. The foldable building units as illustrated in FIGS. 7 to 73 have each an interior wall assembly which is positioned partially or completely within a cavity provided by one or more foldably connected floor sections.

Folding (rotating) the wall assembly into a cavity, especially, with its entire depth or thickness, reduces the width of the foldable building unit in completely folded configuration. This is important because in designing useful and living and working spaces, it has been found that width is the major dimensional constraint if it is desired to transport the folded building unit on a standard truck without the use of special permits. Further, because the cavity is provided on the underside (i.e., the side of a floor section that faces the ground in unfolded configuration of the foldable building unit) of one or more foldably connected floor sections, the one or more foldably connected floor sections can still have finish material on the top surface (i.e., the side opposite to the underside.

A second embodiment of a foldable building unit of the present invention, and a respective exemplary unfolding/folding sequence of the foldable building unit is illustrated in FIGS. 7 to 12. For ease of illustration, the figures do not show the foldable connections (e.g., hinges) which facilitate the folding and unfolding of wall and floor sections as described in the following. FIG. 7A provides an isometric schematic view of a foldable building unit 200 in completely folded configuration. FIGS. 7B to 7E provide front view, right side view, top view and left side view of the foldable building unit 200 in completely folded configuration, respectively. The foldable building unit 200 has two foldably connected floor sections 205 and 210. Each of the floor sections 205 and 210 is rotatedaround a horizontal axis which is parallel to the length direction of the core structure and connected to the core structure 215, specifically, to a fixed floor 220 of the core structure. The floor sections 205 and 210 are further foldably connected, on the ends opposite to the foldable connection to the fixed floor 220, to optional wall sections 225 and 230, respectively. Specifically, the foldably connected optional wall sections 225 and 230 are ratably connected around a further horizontal axis which is also parallel to the length direction of the core structure 215. An interior wall assembly, here one interior wall section 235, is foldably connected to an optional interior core wall section 240 of the core structure 215. In the completely folded configuration of the foldable building unit 200, the foldably connected floor section 210 and the foldably connected optional wall section 230 are folded between the core structure 215 and the interior wall section 235, with the interior wall section 235 being positioned with its entire depth within a cavity on the underside of the foldably connected floor section 210. As a bottom part 260 (see FIG. 7C) of interior wall section 235 extends beyond the cavity provided by the foldably connected floor section 210, interior wall section 235 is partially within the cavity. The interior wall section 235 of this embodiment could be replaced with one that does not extend beyond the cavity; however, interior wall assemblies such as interior wall section 235 which are positioned such that the bottom side (i.e., the side of a wall section in final unfolded position that faces the ground) is below the top surface of the adjacent, foldably connected floor sections (in completely unfolded configuration of the foldable building unit) have the advantage that they are sandwiched between the adjacent unfolded floor sections, which allows for ease of finishing, ease of fastening of the interior wall assembly, and/or improved structural strength of the structural frame of the completed building.

Because the foldable building unit 200 is designed such that the interior wall section 235 folds into an underside cavity of floor section 210, the fixed floor 220 of the core structure 215 typically extends less far beyond the side surfaces 265 of the core's fixed wall sections 270 and 275, compared to the foldable building unit 100.

The foldable building modules of the present invention allow unfolding of the wall assembly, for example, the interior wall section 235 of foldable building module 200 of FIGS. 7A to E, before adjacent foldably connected floor sections, e.g., floor sections 205 and 210, are unfolded. This in turn allows prefabricating these floor sections, for example, floor sections 205 and 210, with finished top surfaces while requiring no clearance between the bottom sides of the interior wall assembly, for example, bottom side of the interior wall section 235 and finished floor surfaces. In fact, in this embodiment the folding interior wall extends beyond the finished floor, that is, exhibits a negative clearance.

Typically, the interior wall assembly is the first to be moved from the folded position to a position which allows adjacent floor sections to be unfolded. However, floor sections that are not folded between the core structure and the interior wall assembly can also be unfolded before the interior wall assembly is moved out of its folded configuration. For example, with regard to the foldable building module 200 as shown in FIGS. 7 to 12, foldably connected floor section 205 can be unfolded before interior wall section 235 is unfolded out of its folded, side by side position with floor section 110.

FIG. 8 A provides an isometric schematic view of the foldable building unit

200 in which the interior wall section 235 has been unfolded into final, unfolded position. FIGS. 8B to 8E provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 200.

FIG. 9 A provides an isometric schematic view of the foldable building unit 200 in which the interior wall section 235 and the floor section 210 have been unfolded into final, unfolded position. As the optional wall section 230 is foldably connected with floor section 210 at the top (with reference to the completely folded configuration) of the floor section 210, unfolding the floor section 210 from folded to unfolded position also moves optional wall section 230. FIGS. 9B to 9E provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 200. The foldable building unit 200 has a core structure 215 which includes a fixed wall section 245 which, in completely folded configuration of the foldable building unit 200 is side -by-side with optional wall section 230. The fixed wall section 245 is also optional, that is, other foldable building modules can be identical to foldable building module 200 but do not have the fixed wall section 245. The fixed wall section 245 separates the core area from the area provided by the unfolded sections thereby forming rooms in the unfolded foldable building unit.

FIG. 10A provides an isometric schematic view of the foldable building unit 200 in which the interior wall section 235, the floor section 210, and the floor section 205 have been unfolded into final, unfolded position. As the optional wall section 225 is foldably connected with floor section 205 at the top (with reference to the completely folded configuration) of the floor section 205, unfolding the floor section 205 from folded to unfolded position also moves optional wall section 225. FIGS. 10B to 10E provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 200. The foldable building unit 200 has a core structure 215 which includes a fixed wall section 250 which, in completely folded configuration of the foldable building unit 200, is side- by- side with optional wall section 225. The fixed wall section 250 is also optional, that is, other foldable building modules can be identical to foldable building module 200 but do not have the fixed wall section 250. Also, fixed wall section 250 and fixed wall section 245 can be combined to be a single wall section, or divided into further fixed or even foldably connected wall sections. The fixed wall section 250 separates the core area from the area provided by the unfolded sections and provides an opening between the core area and the area provided by the unfolded sections.

FIG. 11 A provides an isometric schematic view of the foldable building unit 200 in which the interior wall section 235, the floor section 210, the floor section 205, and wall section 230 have been unfolded into final, unfolded position. FIGS. 1 IB to 1 IE provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 200.

FIG. 12A provides an isometric schematic view of the foldable building unit 200 in which the interior wall section 235, the floor section 210, the floor section 205, and wall section 230 have been unfolded into final, unfolded position. FIGS. 12B to 12E provide respective front view, right side view, top view and left side view of this configuration of the foldable building unit 200.

The foldable building units of the present invention have at least one floor section which is foldably connected to the core structure of the foldable building unit. Typically, the foldable building unit has one, two, three, four, or up to six floor sections that are each foldably connected to the core structure. In some

embodiments the foldable building units have two foldably connected floor sections, one on each side of an interior wall assembly. For example, the foldable building units 100 and 200 of FIGS 1 to 6 and 7 to 12, respectively, have two foldably connected floor sections. However, although the number of floor sections directly foldably connected to a fixed floor of the core structure is not limited in principle, with an increasing number of foldably connected floor sections the prefabrication process is more costly and, after unfolding at the building side, the extent of required finishing can be increased because of seams between the unfolded floor sections. On the other hand, smaller floor sections and respective smaller wall sections connected to same can allow for easier unfolding because of the reduced weight. Further, typically, the floor sections are foldably connected with optional wall sections with, typically, at least one foldably connected optional wall section per foldably connected floor section. An exemplary embodiment of a foldable building unit having more than two foldable connected floor sections is illustrated in FIGS. 13 to 22.

A third embodiment of a foldable building unit of the present invention, and a respective exemplary unfolding/folding sequence of the foldable building unit is illustrated in FIGS. 13 to 22. For ease of illustration, the figures do not show the foldable connections (e.g., hinges) which facilitate the folding and unfolding of wall and floor sections as described in the following. FIG. 13 provides an isometric schematic view of a foldable building unit 300 in completely folded configuration. The foldable building unit 300 has four foldably connected floor sections 305, 306, 308 and 310. Each of the floor sections 305, 306, 308 and 310 is able to be rotated around a horizontal axis which is parallel to the length direction of the core structure 315 and is connected to the core structure 315, specifically, to a fixed floor 320 of the core structure 315. The floor sections 305, 306, 308 and 310 are each further foldably connected, on the ends opposite to the foldable connection to the fixed floor 320, to optional wall sections 325, 326, 328 and 330, respectively. Specifically, the foldably connected optional wall sections 325, 326, 328 and 330 are ratably connected around a further horizontal axis which is also parallel to the length direction of the core structure 315. An interior wall assembly, here one interior wall section 335, is foldably connected to an optional interior core wall section 340 of the core structure 315. In the completely folded configuration of the foldable building unit 300, the foldably connected floor sections 308 and 310, and the respective foldably connected optional wall sections 328 and 230 are folded between the core structure 315 and the interior wall section 335, with the interior wall section 335 being positioned with its entire depth within a cavity on the underside of the foldably connected floor sections 308 and 310.

FIG. 14 provides an isometric schematic view of the foldable building unit 300 in which the interior wall section 335 has been unfolded into final, unfolded position. FIG. 15 provides an isometric schematic view of the foldable building unit 300 in which the interior wall section 335 and the floor section 308 have been unfolded into final, unfolded position. In this embodiment, floor section 308 is the first floor section that has been unfolded into final position; however, any one of foldably connected floor sections 305, 306, 308 and 310 can be unfolded first, or one or more of these sections can be unfolded concurrently. As optionalwall section 328 is foldably connected with floor section 308 at the top (with reference to the completely folded configuration) of the floor section 308, unfolding the floor section 308 from folded to unfolded position also moves the optionalwall section 328. The foldable building unit 300 has a core structure 315 which includes a fixed wall section 345 which, in completely folded configuration of the foldable building unit 300 is side-by-side with optionalwall section 328. The fixed wall section 345 is also optional.

FIG. 16 provides an isometric schematic view of the foldable building unit 300 in which the interior wall section 335, the floor section 308, and the floor section 310 have been unfolded into final, unfolded position. As the optional wall section 330 is foldably connected with floor section 310 at the top (with reference to the completely folded configuration) of the floor section 310, unfolding the floor section 310 from folded to unfolded position also moves optional wall section 330.

FIG. 17 provides an isometric schematic view of the foldable building unit

300 in which the interior wall section 335, the floor section 308, the floor section 310, and the optional wall section 328 have been unfolded into final, unfolded position.

FIG. 18 provides an isometric schematic view of the foldable building unit 300 in which the interior wall section 335, the floor section 308, the floor section

310, the optional wall section 328, and optional wall section 330 have been unfolded into final, unfolded position.

FIG. 19 provides an isometric schematic view of the foldable building unit 300 in which the interior wall section 335, the floor section 308, the floor section 310, the optional wall section 328, the optional wall section 330 and floor section 305 have been unfolded into final, unfolded position. In this isometric view, floor sections 308 and 310 are not visible; however, they are positioned as is illustrated in FIG. 18. As the optional wall section 325 is foldably connected with floor section 305 at the top (with reference to the completely folded configuration) of the floor section 305, unfolding the floor section 305 from folded to unfolded position also moves the optional wall section 325.

FIG. 20 provides an isometric schematic view of the foldable building unit

300 in which the interior wall section 335, the floor section 308, the floor section 310, the optional wall section 328, the optional wall section 330, the floor section 305 and the floor section 306 have been unfolded into final, unfolded position. In this isometric view, floor sections 308 and 310 are not visible; however, they are positioned as is illustrated in FIG. 18. As the optional wall section 326 is foldably connected with floor section 306 at the top (with reference to the completely folded configuration) of the floor section 306, unfolding the floor section 306 from folded to unfolded position also moves optional wall section 326.

FIG. 21 provides an isometric schematic view of the foldable building unit 300 in which the interior wall section 335, the floor section 308, the floor section 310, the optional wall section 328, the optional wall section 330, the floor section 305, the floor section 306, and the optional wall section 325 have been unfolded into final, unfolded position.

FIG. 22 provides an isometric schematic view of the foldable building unit 300 in which the interior wall section 335, the floor section 308, the floor section 310, the optional wall section 328, the optional wall section 330, the floor section 305, the floor section 306, the optional wall section 325, and the optional wall section 326 have been unfolded into final, unfolded position.

The wall assembly of the present invention can be an interior wall assembly or an exterior wall assembly, and it can be one wall section or be comprised of a plurality of foldably connected wall sections. An exterior wall assembly forms an exterior wall of the foldable building unit or building, with at least one side facing the outside when the building is finished. An interior wall assembly forms an interior wall within the unfolded building unit or finished building. Typically, the exterior wall assembly is foldably connected to the core structure in a position close to or at an end of the core structure. A "section" of a wall, floor or roof is one integral building element. Two foldable connected sections, for example, two foldably connected wall sections do not constitute a wall section, rather they constitute a "wall assembly" which in final, unfolded configuration can form part of or an entire wall. An exemplary

embodiment of a foldable building unit having an interior wall assembly comprised of a plurality of foldably connected interior wall sections is illustrated in FIGS. 23 to 29.

A fourth embodiment of a foldable building unit of the present invention, and a respective exemplary unfolding/folding sequence of the foldable building unit is illustrated in FIGS. 23 to 29. For ease of illustration, the figures do not show the foldable connections (e.g., hinges) which facilitate the folding and unfolding of wall and floor sections as described in the following. FIG. 23 provides an isometric schematic view of a foldable building unit 400 in completely folded configuration. The foldable building unit 400 has two foldably connected floor sections 405 and 410. Each of the floor sections 405 and 410 is rotates around a horizontal axis which is parallel to the length direction of the core structure and connected to the core structure 415, specifically, to a fixed floor 420 of the core structure. The floor sections 405 and 410 are further foldably connected, on the ends opposite to the foldable connection to the fixed floor 420, to optional wall sections 425 and 430, respectively. Specifically, the foldably connected optional wall sections 425 and 430 are ratably connected, around a further horizontal axis which is also parallel to the length direction of the core structure 415 to the floor sections 405. An interior wall assembly comprised of two interior wall sections 435 and 437, is foldably connected to an interior optional core wall section 440 of the core structure 415, specifically, interior wall section 437 is, at a first end, foldably connected to the optional interior core wall section 440, and, at a second end opposite to the first end, foldably connected to the first interior wall section 435. In the completely folded configuration of the foldable building unit 400, the foldably connected floor section 410 and the foldably connected optional wall section 430 are folded between the core structure 415 and the interior wall assembly comprised of interior wall sections 435 and 437, with the interior wall assembly being positioned with its entire depth within a cavity on the underside of the foldably connected floor section 410. In an alternative embodiment, the interior wall assembly can be partially within the cavity, for example, only interior wall section 437 can be partially or completely within the cavity and interior wall section 435 can be completely or partially outside of the cavity, in a side-by-side arrangement with interior wall section 437. In a further alternative embodiment, the interior wall assembly can be folded such that it sits entirely outside of the floor cavity.

FIG. 24 provides an isometric schematic view of the foldable building unit 400 in which the interior wall section 437 has been unfolded into final, unfolded position. As interior wall section 435 is foldably connected to second interior wall section 437, unfolding interior wall section 437 also moves interior wall section 435.

FIG. 25 provides an isometric schematic view of the foldable building unit 400 in which the interior wall sections 435 and 437 have been unfolded into final, unfolded position. The interior wall sections 435 and 437, and the optional interior core wall section 440 form one continuous wall within the completely unfolded building unit.

FIG. 26 provides an isometric schematic view of the foldable building unit 400 in which the interior wall sections 435 and 437, and the floor section 405 have been unfolded into final, unfolded position. As the optional wall section 425 is foldably connected with floor section 405 at the top end (with reference to the completely folded configuration) of the floor section 405, unfolding the floor section 405 from folded to unfolded position also moves optional wall section 425. The foldable building unit 400 has a core structure 415 which includes a fixed wall section 450 which, in completely folded configuration of the foldable building unit 400, is side-by-side with wall section 425. Analogously to, for example, foldable building unit 200, the fixed wall section 450 is optional.

FIG. 27 provides an isometric schematic view of the foldable building unit 400 in which the interior wall sections 435 and 437, the floor section 405, and the floor section 410 have been unfolded into final, unfolded position. As the optional wall section 430 is foldably connected with floor section 410 at the top (with reference to the completely folded configuration) of the floor section 410, unfolding the floor section 410 from folded to unfolded position also moves optional wall section 430. FIG. 28 provides an isometric schematic view of the foldable building unit 400 in which the interior wall sections 435 and 437, the floor section 405, the floor section 410, and the optional wall section 430 have been unfolded into final, unfolded position.

FIG. 28 provides an isometric schematic view of the foldable building unit

400 in which the interior wall sections 435 and 437, the floor section 405, the floor section 410, and the optional wall section 430 have been unfolded into final, unfolded position.

FIG. 29 provides an isometric schematic view of the foldable building unit 400 in which the interior wall sections 435 and 437, the floor section 405, the floor section 410, the optional wall section 430, and the other optional wall section 425 have been unfolded into final, unfolded position.

The interior wall assemblies of the foldable building units of the present invention are foldably connected to the core structure. Typically, an interior wall assembly is foldably connected to an interior core wall section of the core structure of the foldable building unit; however, generally, the interior wall assemblies can be foldably connected to any part of the core structure that is structurally adapted to support such foldable connection. For example, interior wall assemblies can foldably connected to structural beams (particularly, steel beams) of the core structure. An exemplary embodiment of a foldable building unit of the present invention which includes an interior wall assembly which is connected to structural beams is illustrated in FIGS. 30 to 35.

A fifth embodiment of a foldable building unit of the present invention, and a respective exemplary unfolding/folding sequence of the foldable building unit is illustrated in FIGS. 30 to 35. For ease of illustration, the figures do not show the foldable connections (e.g., hinges) which facilitate the folding and unfolding of wall and floor sections as described in the following. FIG. 30 provides an isometric schematic view of a foldable building unit 500 in completely folded configuration. The foldable building unit 500 has two foldably connected floor sections 505 and 510. Each of the floor sections 505 and 510 is rotates around a horizontal axis which is parallel to the length direction of the core structure 515 and connected to the core structure 515, specifically, to a fixed floor 520 of the core structure. The floor sections 505 and 510 are further foldably connected, on the ends opposite to the foldable connection to the fixed floor 520, to optional wall sections 525 and 530, respectively. Specifically, the foldably connected optional wall sections 525 and 530 are ratably connected around a further horizontal axis which is also parallel to the length direction of the core structure 515. An interior wall assembly, here one interior wall section 535, is foldably connected to two structural beams of the core structure 515, one structural beam 541 positioned at ceiling height and one structural beam 543 positioned at floor level. In the completely folded configuration of the foldable building unit 500, the foldably connected floor section 510 and the foldably connected optional wall section 530 are folded between the core structure 515 and the interior wall section 535, with the interior wall section 535 being positioned with its entire depth within a cavity on the underside of the foldably connected floor section 510. As in previous embodiments, this foldable interior wall section could alternatively be folded such that it only sits partially within this cavity or fully to the exterior of this cavity.

FIG. 31 provides an isometric schematic view of the foldable building unit 500 in which the interior wall section 535 has been unfolded into final, unfolded position.

FIG. 32 provides an isometric schematic view of the foldable building unit 500 in which the interior wall section 535 and the floor section 510 have been unfolded into final, unfolded position. As the optional wall section 530 is foldably connected with floor section 510 at the top (with reference to the completely folded configuration) of the floor section 510, unfolding the floor section 510 from folded to unfolded position also moves the optional wall section 530. The foldable building unit 500 has a core structure 515 which includes a fixed interior wall section 545. The fixed wall section 545 is optional.

FIG. 33 provides an isometric schematic view of the foldable building unit 500 in which the interior wall section 535, the floor section 510, and the floor section 505 have been unfolded into final, unfolded position. As the optional wall section 525 is foldably connected with floor section 505 at the top (with reference to the completely folded configuration) of the floor section 505, unfolding the floor section 505 from folded to unfolded position also moves optional wall section 525. FIG. 34 provides an isometric schematic view of the foldable building unit 500 in which the interior wall section 535, the floor section 510, the floor section 505, and the optional wall section 530 have been unfolded into final, unfolded position.

FIG. 35 provides an isometric schematic view of the foldable building unit

500 in which the interior wall section 535, the floor section 510, the floor section 505, the optional wall section 530, and the other optional wall section 525 have been unfolded into final, unfolded position.

In certain embodiments of the present invention, the foldable building units include one or more floor sections that provide a cavity for an interior wall assembly. Typically, the cavity is dimensioned to match one or more of the interior wall assemblies dimensions. However, the cavity can also exceed height, width and/or depth of the interior wall assembly (e.g., of one or more foldably connected interior wall sections).

FIG. 36 illustrates a sixth embodiment of a foldable building module of the present invention in completely folded configuration. The only difference between the illustrated foldable building module 600 and the foldable building module 200 of FIGS. 7 to 12 is that the interior wall section 635 has a smaller width than interior wall section 235. Thus, the interior wall in the unfolded building unit will not span from the core to the outside wall, and instead leave an opening.

FIG. 37 illustrates a seventh embodiment of a foldable building module of the present invention in completely folded configuration. The only difference between the illustrated foldable building module 700 and the foldable building module 200 of FIGS. 7 to 12 is that the interior wall section 735 has a greater width than interior wall section 235. Thus, the interior wall in the unfolded building unit will extend beyond the outside wall.

FIG. 38 illustrates an eighth embodiment of a foldable building module of the present invention in completely folded configuration. The illustrated foldable building module 800 differs from the foldable building module 200 of FIGS. 7 to 12 in that the interior wall section 835 has a smaller thickness than interior wall section 235. Accordingly, foldably connected floor sections 805 and 810, and foldably connected wall sections 825 and 835, are wider than respective sections 205, 210, 225, and 230 of foldable building unit 200, such that the space 870 is sufficiently but not too large. Generally, the space between the foldably connected floor sections (foldably connected to the core structure) and any foldably connected wall sections (foldably connected to the foldably connected floor sections) is dimensioned be large enough to accommodate placement of the interior wall assembly in the space; however, to minimize finishing after unfolding at the building site it is desirable to keep the clearance between the sides of the interior wall and other floor and/or wall sections as small as possible .

FIG. 39 illustrates a ninth embodiment of a foldable building module of the present invention in completely folded configuration. The illustrated foldable building module 900 differs from the foldable building module 200 of FIGS. 7 to 12 in that the interior wall section 935 has a greater thickness than interior wall section 235.

FIG. 40 illustrates a tenth embodiment of a foldable building module of the present invention in completely folded configuration. The illustrated foldable building module 1000 differs from the foldable building module 200 of FIGS. 7 to 12 in that the interior wall section 1035 is entirely within a cavity provided by the foldably connected floor section 1210.

As used herein, a wall assembly that is "entirely within a cavity" is a wall assembly that is (1) in its entire thickness within the cavity, and (2) all of the wall assembly's sides, with the possible exception of the side which has the foldable connection, are within the cavity provided by structural material (including, e.g., floor sheathing and structural frame such as steel floor frame) of one or more foldably connected floor sections.

The foldably connected floor sections of the foldable building units of the present invention which provide a cavity for the interior wall assembly can comprise a three member u-shaped steel floor frame in fixed connection with floor sheathing. Some or all of the floor supports, e.g. joists (typically, wood joists), are removed as long as the interior wall assembly is nested in the cavity, i.e., joists can be installed on the underside, including within the cavity, once the interior wall assembly has been removed from the cavity. This installation is typically very quick and need not impede the ability to complete finishes during prefabrication. FIG. 40 provides such an exemplary foldable fioor section 1210 being comprised of three steel members 1211, 1212 and 1213, to which floor sheathing 1214 is attached.

The foldable building units of the present invention can include a plurality of floor sections connected in series such that a first floor section is foldably connected to the core structure on a first side and foldable connected to a second floor section at a second side, opposite to first side. The second floor section can further be connected, at a third side opposite to the second side, to a third f oor section. In this manner, a plurality of floor sections can be foldably connected in series. Typically, the number of floor sections in a series of foldably connected floor sections is one, two, three or four. More typically, it is one or two. To provide floor on both sides of the interior wall assembly, when series of foldably connected floor sections are used, at least one series of foldably connected floor sections provides the floor on a first side of the interior wall assembly and another series of foldably connected floor sections or a single floor section foldably connected to the core structure provides the floor on a second side of the interior wall assembly. Alternatively, the wall assembly can be located at one extremity along the length of the building, thus requiring only one series of foldably connected floor sections.

An exemplary embodiment of a foldable building unit having series of foldably connected floor sections is illustrated in FIGS. 41 to 48.

An 11^th embodiment of a foldable building unit of the present invention, and a respective exemplary unfolding/folding sequence of the foldable building unit is illustrated in FIGS. 41 to 48. For ease of illustration, the figures do not show the foldable connections (e.g., hinges) which facilitate the folding and unfolding of wall and floor sections as described in the following. FIG. 41 provides an isometric schematic view of a foldable building unit 1100 in completely folded configuration. The foldable building unit 1100 has four foldably connected floor sections 1105, 1106, 1108 and 1110. Each of the floor sections 1105, 1106, 1108 and 1110 is rotated around a horizontal axis, which is parallel to the length direction of the core structure 1115 and connected to the core structure 1115, specifically, to a fixed floor 1120 of the core structure 1115. The fioor sections 1106 and 1108 are each further foldably connected, on the ends opposite to the foldable connection to the fixed floor 1120, to optional wall sections 1125 and 1130 (visible in FIGS. 45 to 48), respectively. Specifically, the foldably connected optional wall sections 1125 and 1130 are rotably connected, around a further horizontal axis, which is also parallel to the length direction of the core structure 1115. An interior wall assembly, here having two interior wall sections 1135 and 1137, which are designed to form one continuous, planar interior wall in final, unfolded position, is foldably connected to an interior core wall section 1140 of the core structure 1115 (as can be seen in FIGS. 43 to 48). In the completely folded configuration of the foldable building unit 1100, the foldably connected floor sections 1108 and 1110, and the respective foldably connected optional wall section 1130 are folded between the core structure 1115 and the interior wall section composed of interior wall sections 1135 and 1137, with the interior wall assembly being positioned with its entire depth within a cavity on the underside of the foldably connected floor section 1110.

FIG. 42 provides an isometric schematic view of the foldable building unit 1100 in which the interior wall sections 1135 and 1137 are being unfolded.

FIG. 43 shows the interior wall assembly in final unfolded position providing one continuous, planar interior wall.

FIG. 44 provides an isometric schematic view of the foldable building unit 1100 in which the interior wall sections 1135 and 1137 are in find unfolded position, and floor sections 1105 and 1110 are in final unfolded position. As the optional wall sections 1125 and 1130 are foldably connected with floor sections 1106 and

1108, respectively, and floor sections 1106 and 1108 are foldably connected to floor sections 1105 and 1110, respectively, unfolding the floor sections 1105 and 1108 from folded to unfolded position also moves floor sections 1106 and 1108 and optional wall sections 1125 and 1130. In other words, floor sections 1105 and 1106 are connected in series, or form a series of foldably connected floor sections, and floor sections 1110 and 1108 are connected in series, or form a series of foldably connected floor sections. The foldable building unit 1100 has a core structure 1115 which includes a fixed wall section 1145 which, in completely folded configuration of the foldable building unit 1100 is side-by-side with floor sections 1106 and 1108. The fixed wall section 1145 is optional. FIG. 45 provides an isometric schematic view of the foldable building unit 1100 in which the interior wall sections 1135 and 1137, and the floor sections 1105, 1110, and 1108 have been unfolded into final unfolded position.

FIG. 46 provides an isometric schematic view of the foldable building unit 1100 in which the interior wall sections 1135 and 1137, and the floor sections 1105, 1106, 1110, and 1108 have been unfolded into final unfolded position.

FIG. 47 provides an isometric schematic view of the foldable building unit 1100 in which the interior wall sections 1135 and 1137, the floor sections 1105, 1106, 1110, and 1108, and optional wall section 1130 have been unfolded into final unfolded position.

FIG. 48 provides an isometric schematic view of the foldable building unit 1100, in completely unfolded configuration, in which the interior wall sections 1135 and 1137, the floor sections 1105, 1106, 1110, and 1108, and optional wall sections 1125 and 1130 have been unfolded into final unfolded position.

The foldable building units of the present invention, in completely unfolded configuration, can have a first, adjacent floor section (e.g., floor section 1106 of the building unit 1100, or floor section 205 of foldable building unit 200) on a first side of the interior wall assembly and a second, adjacent floor section (e.g., floor section 1108 of the building unit 1100, or floor section 210 of foldable building unit 200) on a second side of the interior wall assembly, the second side being opposite the first side; and a first optional wall section foldably connected to the first floor section and a second optional wall section foldably connected to the second floor section, wherein the first optional wall section and the second optional wall section, each, provide an outside surface of the foldable building unit in completely unfolded configuration. Alternatively, the interior wall assembly can be located at one extremity along the length of the building, thus requiring only one foldably connected floor section and only one optional foldable wall section.

Typically, the interior wall assembly is either one interior wall or it comprises a plurality of foldably connected interior wall sections which, in final unfolded position, provide one continuous, planar wall, typically, spanning the width from the core to the outside wall sections. However, when the interior wall assembly comprises a plurality of interior wall sections, it can also provide an interior wall which is not straight, that is, forms corners, and can but does not have to span the entire width between the core structure and the wall sections providing an outside wall. However, this requires the interior wall to be moved over flooring (typically, finished flooring), which is less desirable for the reasons described above. For the interior wall assembly to be able to move into final position over flooring, a sufficient clearance between the bottom side of the interior wall assembly and the flooring is required to prevent damage to the flooring during the folding/unfolding movement. The amount of minimum clearance depends on a number of factors, including dimensions and weight of the interior wall assembly, dimension and type of hinges, how the interior wall assembly is unfolded (e.g., with or without help of a crane), the structural composition of the core structure, and building tolerances. A typical minimum clearance is about 2.5 cm. The larger the clearance, the more finishing is required on site which is not desirable.

A 12^th embodiment of a foldable building unit of the present invention, and a respective exemplary unfolding/folding sequence of the foldable building unit, is illustrated in FIGS. 49 to 58. For ease of illustration, the figures do not show the foldable connections (e.g., hinges) which facilitate the folding and unfolding of wall and floor sections as described in the following. FIG. 49 provides an isometric schematic view of a foldable building unit 1200 in completely folded configuration. The foldable building unit 1200 has two foldably connected floor sections 1205 and 1210. Each of the floor sections 1205 and 1210 is rotatable around a horizontal axis, which is parallel to the length direction of the core structure, connected to the core structure 1215, specifically, to a fixed floor 1220 of the core structure. The floor sections 1205 and 1210 are further foldably connected, on the ends opposite to the foldable connection to the fixed floor 1220, to optional wall sections 1225 and 1230, respectively. Specifically, the foldably connected optional wall sections 1225 and 1230 are ratably connected around a further horizontal axis, which is also parallel to the length direction of the core structure 1215. An interior wall assembly comprised of three interior wall sections 1235, 1237 and 1239 is foldably connected to an optional interior core wall section 1240 (visible, e.g., in FIG. 53) of the core structure 1215, specifically, the interior wall section 1239 is, at a first end, foldably connected to the optional interior core wall section 1240, and, at a second end opposite to the first end, foldably connected to the interior wall section 1237, which in turn is likewise foldably connected to interior wall section 1239. In the completely folded configuration of the foldable building unit 1200, the foldably connected floor section 1210 and the foldably connected wall section 1230 are folded between the core structure 1215 and the interior wall assembly comprised of interior wall sections 1235, 1237 and 1239, with the interior wall assembly being positioned with its entire depth within a cavity on the underside of the foldably connected floor section 1210.

FIG. 50 provides an isometric schematic view of the foldable building unit 1200 in which the interior wall assembly has been moved out of folded position but is not yet in a position that allows unfolding of the adjacent floor and wall sections. Typically, the floor and wall sections can be unfolded when the interior wall assembly is in a straight position; however, if the space between the adjacent floor and wall sections is designed to be wider than the thickness of the interior wall assembly, the interior wall assembly does not have to be entirely straight to allow unfolding of the adjacent floor (1205 and 1210) and optional wall sections (1225 and 1230). Also, because the interior wall assembly in this embodiment is designed to be able to move over flooring to form a final interior wall that has corners, the space between the adjacent floor and wall sections has to be larger than in embodiments in which the interior wall assembly forms one straight interior wall in final

configuration, because the interior wall section which is sandwiched between the final unfolded optional wall sections 1225 and 1230, it needs to be able to move out of the space.

FIG. 51 provides an isometric schematic view of the foldable building unit 1200 in which the interior wall sections 1235, 1237 and 1239 have been unfolded into a position (here planar or straight position) that allows subsequent unfolding of the adjacent floor and wall sections.

FIG. 52 provides an isometric schematic view of the foldable building unit 1200 in which the interior wall sections 1235, 1237 and 1239 have been unfolded into a position that allows subsequent unfolding of the adjacent floor and optional wall sections, and floor section 1210 is in final unfolded position. As the optional wall section 1230 is foldably connected with floor section 1210 at the top end (with reference to the completely folded configuration) of the floor section 1210,

unfolding the floor section 1210 from folded to unfolded position also moves optional wall section 1230. The foldable building unit 1200 has a core structure 1215 which includes a fixed wall section 1250 which, in completely folded configuration of the foldable building unit 1200, is side-by-side with optional wall sections 1225 and 1230. For the reasons described above, for example, with regard to foldable building unit 200, the fixed wall sections such as 1250 are optional.

FIG. 53 provides an isometric schematic view of the foldable building unit 1200 in which the interior wall sections 1235, 1237 and 1239 have been unfolded into a position that allows unfolding of the adjacent floor and optional wall sections, and floor sections 1205 and 1210 are in final unfolded position. As the optional wall section 1225 is foldably connected with floor section 1205 at the top end (with reference to the completely folded configuration) of the floor section 1205,

unfolding the floor section 1205 from folded to unfolded position also moves optional wall section 1225.

FIG. 54 provides an isometric schematic view of the foldable building unit 1200 in which the interior wall sections 1235, 1237 and 1239 have been unfolded into a position that allows unfolding of the adjacent floor and wall sections, and floor sections 1205 and 1210, and wall section 1230 are in final unfolded position.

FIG. 55 provides an isometric schematic view of the foldable building unit

1200 in which the interior wall sections 1235, 1237 and 1239 have been unfolded into a position that allows unfolding of the adjacent floor and optional wall sections, and floor sections 1205 and 1210, and optional wall sections 1225 and 1230 are in final unfolded position. The distance 1290 between optional wall sections 1225 and 1230 is designed to be sufficiently large to allow the interior wall assembly to be moved from between the wall sections, for example, as shown in FIG. 56.

FIG. 56 provides an isometric schematic view of the foldable building unit 1200 in which the interior wall sections 1235, 1237 and 1239 are positioned such that none of the wall sections is between optional wall sections 1225 and 1230. Further, floor sections 1205 and 1210, and wall sections 1225 and 1230 are in final unfolded position. FIG. 57 provides an isometric schematic view of the foldable building unit 1200 in which the interior wall sections 1235, 1237 and 1239 are positioned such that none of the wall sections is between optional wall sections 1225 and 1230. The three wall sections form a non-planar interior wall. Further, floor sections 1205 and 1210, and optional wall sections 1225 and 1230 are in final unfolded position.

FIG. 58 provides an isometric schematic view of the foldable building unit 1200 in which the interior wall sections 1235, 1237 and 1239 are positioned such that none of the wall sections is between optional wall sections 1225 and 1230. The three wall sections form a non-planar interior wall. Further, floor sections 1205 and 1210, and optional wall sections 1225 and 1230 are in final unfolded position. Blocking 1295 has been installed between wall sections 1225 and 1230.

Foldable building units of the present invention such as the 12^th embodiment illustrated in FIGS. 49-58, can have an interior wall assembly which comprises a plurality of foldably connected interior wall sections. As is the case for the building unit 1200, the combined width of the wall sections can be greater than the distance between the interior core wall section and the foldably connected optional wall sections that form the exterior wall. If the combined width is greater, it can allow a non-planar wall that spans between the core structure and the wall sections that form the exterior wall. However, typically this means that the interior wall assembly is folded within the floor cavity such that the interior wall sections are

stacked,increasing the width of foldable building unit in completely folded configuration. Alternatively, the interior wall sections can be positioned within the floor cavity in a non-stacked/planar arrangement as is shown in FIGS. 59 to 67, which has the advantage that the width of the building unit in completely folded configuration is reduced. In these cases, part of the interior wall assembly can extend beyond the length of the core structure, or the position of the interior core wall section of the core structure can be positioned sufficiently off-center (along the length dimension of the core structure) such that none of the interior wall assembly extends beyond the length of the core structure. The latter is the case for the embodiment illustrated in FIGS. 59 to 67.

A 13^th embodiment of a foldable building unit of the present invention, and a respective exemplary unfolding/folding sequence of the foldable building unit is illustrated in FIGS. 59 to 67. For ease of illustration, the figures do not show the foldable connections (e.g., hinges) which facilitate the folding and unfolding of wall and floor sections as described in the following. FIG. 59 provides an isometric schematic view of a foldable building unit 1300 in completely folded configuration. The foldable building unit 1300 has two foldably connected floor sections 1305 and 1310. Each of the floor sections 1305 and 1310 is connected ratably around a horizontal axis, which is parallel to the length direction of the core structure, connected to the core structure 1315, specifically, to a fixed floor 1320 of the core structure. The floor sections 1305 and 1310 are further foldably connected, on the ends opposite to the foldable connection to the fixed floor 1320, to optional wall sections 1325 and 1330, respectively. Specifically, the foldably connected optional wall sections 1325 and 1330 are ratably connected, around a further horizontal axis, which is also parallel to the length direction of the core structure 1315. An interior wall assembly comprised of three interior wall sections 1335, 1337 and 1339 is foldably connected to an optional interior core wall section 1340 (visible, e.g., in FIG. 62) of the core structure 1315, specifically, interior wall section 1339 is, at a first end, foldably connected to the interior core wall section 1340, and, at a second end opposite to the first end, foldably connected to the interior wall section 1337, which in turn is likewise foldably connected to interior wall section 1339. In the completely folded configuration of the foldable building unit 1300, the foldably connected floor section 1310 and the foldably connected optional wall section 1330 are folded between the core structure 1315 and the interior wall assembly comprised of interior wall sections 1335, 1337 and 1339, with the interior wall assembly being positioned with its entire depth within a cavity on the underside of the foldably connected floor section 1310.

FIG. 60 provides an isometric schematic view of the foldable building unit 1300 in which the interior wall assembly has been moved out of folded position and into a position that allows unfolding of the adjacent floor and wall sections.

Typically, the floor and wall sections can be unfolded when the interior wall assembly is in a straight position; however, if the space between the adjacent floor and wall sections is designed to be larger than the interior wall assembly does not have to be entirely straight to allow unfolding of the adjacent floor (1305 and 1310) and optional wall sections (1325 and 1330). Also, because the interior wall assembly in this embodiment is designed to be able to move over flooring to form a final interior wall that has corners, the space between the adjacent floor and wall sections has to be larger than in embodiments in which the interior wall assembly forms one straight interior wall in final configuration, to allow the interior wall assembly to moved into final position.

FIG. 61 provides an isometric schematic view of the foldable building unit 1300 in which the interior wall sections 1335, 1337 and 1339 have been unfolded into a position that allows subsequent unfolding of the adjacent floor and optional wall sections, and floor section 1310 is in final unfolded position. As the optional wall section 1330 is foldably connected with floor section 1310 at the top end (with reference to the completely folded configuration) of the floor section 1310, unfolding the floor section 1310 from folded to unfolded position also moves optional wall section 1330. The foldable building unit 1300 has a core structure 1315 which includes a fixed wall section 1350 which, in completely folded configuration of the foldable building unit 1300, is side-by-side with wall section 1330. For the reasons described above, for example, with regard to foldable building unit 200, the fixed wall sections such as 1350 are optional.

FIG. 62 provides an isometric schematic view of the foldable building unit 1300 in which the interior wall sections 1335, 1337 and 1339 have been unfolded into a position that allows unfolding of the adjacent floor and optional wall sections, and floor sections 1305 and 1310 are in final unfolded position. As the optional wall section 1325 is foldably connected with floor section 1305 at the top end (with reference to the completely folded configuration) of the floor section 1305, unfolding the floor section 1305 from folded to unfolded position also moves optional wall section 1325.

FIG. 63 provides an isometric schematic view of the foldable building unit 1300 in which the interior wall sections 1335, 1337 and 1339 have been unfolded into a position that allows unfolding of the adjacent floor and optional wall sections, and floor sections 1305 and 1310, and optional wall section 1330 are in final unfolded position. FIG. 64 provides an isometric schematic view of the foldable building unit 1300 in which the interior wall sections 1335, 1337 and 1339 have been unfolded into a position that allows unfolding of the adjacent floor and optional wall sections, and floor sections 1305 and 1310, and optional wall sections 1325 and 1330 are in final unfolded position. The distance 1390 between optional wall sections 1325 and 1330 is designed to be sufficiently large to allow the interior wall assembly to be moved from between the wall sections, for example, as shown in FIG. 65.

FIG. 65 provides an isometric schematic view of the foldable building unit 1300 in which the interior wall sections 1335, 1337 and 1339 are positioned such that none of the foldable interior wall sections is between optional wall sections 1325 and 1330. Further, floor sections 1305 and 1310, and optional wall sections 1325 and 1330 are in final unfolded position.

FIG. 66 provides an isometric schematic view of the foldable building unit 1300 in which the interior wall sections 1335, 1337 and 1339 are positioned such that none of the foldable interior wall sections is between optional wall sections

1325 and 1330. The three foldable interior wall sections form a non-planar interior wall. Further, floor sections 1305 and 1310, and optional wall sections 1325 and 1330 are in final unfolded position.

FIG. 67 provides an isometric schematic view of the foldable building unit 1300 in which the interior wall sections 1335, 1337 and 1339 are positioned such that none of the foldable interior wall sections is between optional wall sections 1325 and 1330. The three foldable interior wall sections form a non-planar interior wall. Further, floor sections 1305 and 1310, and optional wall sections 1325 and 1330 are in final unfolded position. Blocking 1395 has been installed between wall sections 1325 and 1330.

After unfolding of wall, floor and/or roof sections of the foldable building units of the present invention, foldable connections are typically changed into fixed connections. This can be achieved, for example, by fastening respective foldably connected sections with fasteners as known in the art.

Another embodiment of the present invention is a completely finished building formed from one or more of the foldable building units as described herein. Forming a finished building from the foldable building units of the present invention typically includes further connecting separate wall and roof sections to the foldable building units in completely unfolded configuration. For example, the foldable building units in completely unfolded configuration as illustrated in FIGS. 6, 12, 22, 29, 35, 48, 58 and 67, typically, require wall sections to complete the outside wall and one or more roof sections to finish the roof above the area formed by unfolding the foldably connected wall and floor sections of the foldable building unit. A completely finished building is a building that is ready for its intended use.

Wall sections, for example, the wall sections as illustrated in FIGS. 1 to 67 can include doors, windows, openings, and doorways.

The core structures of the present invention have at least one fixed floor and a plurality of wall sections in fixed connection with the fixed floor.

The use of the term "fixed" as modifier for wall, floor, or roof section, as used herein, means that the referred to section is so connected and positioned that it will not be folded or unfolded. In other words, a "fixed" floor, "fixed" wall or "fixed" roof is not folded before transport or unfolded at the building site. A fixed section, for example, a fixed floor can have both fixed connections with one or more sections and foldable connections with one or more sections. A "fixed connection", as used herein, refers to a connection between sections which is not designed to allow folding or unfolding (typically, in rotational manner) of any of the sections that takes part in the connection relative to other sections that take part in the connection.

It should be understood that terms such as horizontal, vertical, parallel, coplanar, and collinear, as used herein, are not of mathematical accuracy and instead mean substantially horizontal, substantially vertical, substantially parallel, substantially coplanar, and substantially collinear.

The foldable building units (e.g., residential homes) of the present invention can be prefabricated such that the foldable buildings units after unfolding on the building site are substantially in finished condition, that is, they do not require the addition of interior and exterior finish materials with the exception of unfinished areas required for folding movement. However, the pre fabrication process can be reduced substantially, even to the extent that merely a foldable structural frame of the present invention is prefabricated and unfolded at the building site. Further, all necessary residential systems for the foldable building, for example, heating, plumbing and electrical, and all the required appliances and plumbing fixtures can be installed in a core structure (i.e., a part of the foldable building unit which is not designed to be unfolded at the building site).

The wall sections of the present invention typically comprise a structural wall frame (preferably a steel frame), wood framing members, wall sheathing, and interior and/or exterior finish material attached to the wall sheathing.

The floor sections of the present invention typically comprise a structural wall frame (preferably a steel frame), wood joists, floor sheathing, and interior and/or exterior finish material attached to the floor sheathing.

Use of appropriately dimensioned metal sections, for example, hollow structural steel sections as shown in FIG. 1, as part of the structural wall and floor frames of the wall and floor sections, respectively, have been found to be

advantageous for a number of reasons including the following. Fewer and/or smaller hinges (typically, metal offset hinges) can be used to foldably connect frame elements, reducing labor and material cost in the prefabrication process, reducing the cost of on-site finishing, and increasing the precision of the folding and unfolding of foldably connected wall and floor sections thereby further reducing the labor and material cost of on-site finishing by enabling prefabrication of interior and exterior materials that fit into the unfinished areas (e.g., seams of foldably connected wall and floor sections) after unfolding. Large and simple structural frame geometries for the wall and floor sections reduce prefabrication cost and/or simplify the folding and unfolding.

Preferably, finish material is indirectly connected to the structural frame of wall and/or floor sections to reduce structural stress transfer from the structural frame to finishing materials, reduce heat loss, and improve moisture control.

Materials and methods to form such indirect connections are described in U.S.

Patent Application No. 13/498,093, entitled "Foldable Building Units, filed

September 23, 2010, incorporated by reference. Further, typically, foldably connected floor and wall sections of the foldable building units of the present invention have foldable connections provided by offset hinges as also described in U.S. Patent Application No. 13/498,093. For ease of illustration hinges are not illustrated in FIGS. 1 to 67. These are typically directly connected to the structural frame (e.g., metal frame) of the wall and floor sections.

The structural frames of the floor and wall sections can include members that are made of a plurality of materials in various forms and dimensions. Suitable materials that can be used include but are not limited to wood, metal (e.g., aluminum or steel) and polymers. Suitable forms include but are not limited to beams, hollow structural sections and channel sections. The selection of a material, form and dimension for a given structural part or member of a structural frame is

interdependent and depends on factors such as the position of the structural part or member in the structural frame, and whether the member is part of a structural frame element that is foldably connected.

Preferably, metal members are made from hot-formed steel. Suitable hot- formed steel includes hollow structural steel sections, I-beams, H-beams and steel channels (typically, C-shaped cross-section). Typically, the hot-formed steel is a hollow structural steel section,a steel channel, or an H-beam. Steel members can be connected by welding, bolting, or screwingto form a steel frame element.

Interior finish materials include but are not limited to wall finishing (for example, glass/ceramic tile, dry wall and wood paneling), ceiling finishing and floor finishing (for example, subflooring with bamboo or hardwood finish flooring on top). Exterior finishing elements include but are not limited to wood siding, fibercement siding, aluminum siding, vinyl siding, roofing, paint, etc.

For finish materials, and, in particular, interior finish materials, it has been found that "indirect connection" to the structural frames of floor and wall sections of the foldable building units to reduce contact, partially or entirely, of the interior finish materials with the frame elements is advantageous for one or more of the following reasons. Reduced contact can (a) reduce the transfer of structural stresses from one or more frame elements of the structural frame to the often fragile and brittle interior finish materials thereby reducing or eliminating significant damage (such as drywall cracking or tile movement) of the interior finish materials, in particular, during folding, uploading, transporting, unloading and/or unfolding of the foldable building unit, (b) reduce or eliminate the exposure of the interior finish materials to water, for example, water that can condensate on metal parts of the frame elements, and (c) reduce heat transfer between the inside of the finished building unit to the outside of the finished building unit. Thus, generally, it is preferred to use indirect rather than direct connections of finish materials, particularly, interior finish materials with respective frame elements. However, even though indirect connections are typically preferred, not all connections between interior finish material and a respective frame element have to be indirect.

The foldable building units of the present invention are foldable to, for example, facilitate transport of the pre-fabricated building units. Preferably, the foldable building units in folded configuration are dimensioned such that transport with a transport vehicle, preferably, a semitrailer does not require a special transport permit. Regulations pertaining to the operation of trucks and trailers vary from country to country, and, in some instances from state to state. For example, currently, in at least one state of the United States of America, the length of a semitrailer including a foldable building unit can be up to 53 feet without requiring a special transport permit, the width of a semitrailer including a foldable building unit can be up to 102 inches without requiring a special transport permit, and the height of a semitrailer including a foldable building unit can be up to 13 feet, 6 inches without requiring a special transport permit.

A "transport vehicle" as referred to herein, is a vehicle that is suited for transporting a foldable building unit along roads to a building site. Typically, the transport vehicle is a semitrailer.

The relevant teachings of all patents, published applications and references cited herein are incorporated by reference in their entirety.

While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.

Claims

CLAIMS What is claimed is:

1. A foldable building unit comprising

(a) a core structure comprising a fixed floor and a plurality of wall sections in fixed connection with the fixed floor;

(b) a floor section foldably connected, on a first side of the core structure, to the fixed floor of the core structure; and

(c) a wall assembly foldably connected to the core structure on the first side of the core structure around a vertical axis; wherein, in completely folded configuration of the foldable building unit, the foldably connected floor section is folded between the core structure and the wall assembly.

2. The foldable building unit of claim 1, wherein the wall assembly is an interior wall assembly.

3. The foldable building unit of claim 1 or 2, wherein the wall assembly, in completely folded configuration of the foldable building unit, (i) is positioned partially or completely within a cavity provided, at least in part, by the foldably connected floor section, or (ii) is positioned side by side the foldably connected floor section.

4. The foldable building unit of any one of claims 1 to 3, wherein the cavity has a depth greater than the thickness of the wall assembly, and the wall assembly, in completely folded configuration of the foldable building unit, is positioned within the cavity with its entire thickness.

5. The foldable building unit of claim 3 or 4, wherein the cavity is provided by one foldably connected floor section.

6. The foldable building unit of any one of claims 1 to 5, wherein the wall assembly comprises a plurality of foldably connected interior wall sections.

7. The foldable building unit of any one of claims 1 to 5, wherein the wall assembly is one wall section.

8. The foldable building unit of any one of claims 1 to 7, wherein the wall assembly is an interior wall assembly foldably connected to an interior core wall section.

9. The foldable building unit of claim 8, wherein the interior core wall section and the interior wall assembly form one continuous wall within the completely unfolded foldable building unit.

10. The foldable building unit of any one of claims 1 to 9, wherein the wall assembly is an interior wall assembly ratably connected around a first rotational axis, the floor section is ratably, around a second rotational axis, connected to the fixed floor section of the core structure of the core structure, the floor section is or is part of a floor having one or more foldably connected floor sections, and the first rotational axis is positioned relative to the first rotational axis such that the interior wall assembly, in completely folded configuration of the foldable building unit (i) is positioned partially or completely within a cavity provided by the floor, or (ii) is positioned side by side with the f oor.

11. The foldable building unit of any one of claims 1 to 10, wherein the wall assembly is an interior wall assembly ratably connected to the core structure around a first rotational axis, a first floor section is ratably, around a second rotational axis connected to the fixed floor section of the core structure, the first rotational axis and the second rotational axis are perpendicular to each other, the first rotational axis is distanced from the second rotational axis, the first rotational axis is distanced away from the fixed floor section of the core structure, and the first floor section is or is part of a floor having one or more foldably connected floor sections; the interior wall assembly, in completely folded configuration of the foldable building unit, (i) being positioned partially or completely within a cavity provided by the floor, or (ii) being positioned side by side with the floor.

12. The foldable building unit of claim 11, wherein the interior wall assembly has a side which faces, in completely folded configuration of the foldable building unit, the floor; and the first rotational axis is distanced from the second rotational axis by a distance, measured along the plane of the first floor section in completely unfolded configuration of the foldable building unit, dependent on the thickness of interior finish material on the side of the interior wall assembly and/or thickness of floor finish material.

13. The foldable building unit of any one of claims 1-12, wherein one side of the wall assembly provides an outside surface of the foldable building unit in completely folded configuration.

14. The foldable building unit of any one of claims 1-13, wherein one side of the wall assembly provides an outside surface of the foldable building unit in completely folded configuration, and the interior wall assembly provides at least two sides with interior finishes in the completed building.

15. The foldable building unit of any one of claims 1-14, wherein, in completely folded configuration of the foldable building unit, the wall assembly is positioned outside the core structure.

16. The foldable building unit of any one of claims 1-15, wherein the foldably connected floor section (i) provides a cavity adapted for partial or complete folding of the wall assembly into the cavity, or (ii) is positioned between the core structure and the wall assembly, in completely folded configuration of the foldable building unit; and the floor section has a finished floor surface.

17. The foldable building unit of any one of claims 1-16, wherein the wall assembly has interior finish material on at least two sides, and the foldably connected floor section has finish material as top surface.

18. The foldable building unit of any one of claims 1-17, wherein the wall

assembly comprises one or more wall sections and each wall section contains steel components.

19. The foldable building unit of any one of claims 1-18, wherein the foldably connected floor section has a finished top surface, and the wall assembly has interior finish material on at least two sides.

20. The foldable building unit of any one of claims 1-19, wherein the wall

assembly is ratably connected to the core structure around the vertical axis; the wall assembly, in completely folded configuration of the foldable building unit, is positioned partly or completely within a cavity of the floor section; the floor section is ratably connected to the fixed floor section of the core structure around a horizontal rotational axis; and, in completely folded configuration of the foldable building unit, the wall assembly and the floor section are vertically positioned.

21. The foldable building unit of any one of claims 1-20, further comprising a wall section foldably connected to a floor provided partly or completely by the floor section which is foldably connected to the fixed floor of the core structure; wherein the foldably connected wall section, the floor and the wall assembly are vertically positioned in the completely folded configuration of the foldable building unit.

22. The foldable building unit of any one of claims 1-21, wherein the foldable building unit, in completely unfolded configuration of the foldable building unit, comprises a foldably connected floor section on each side of the interior wall assembly.

23. The foldable building unit of any one of claims 1-22, wherein a first floor section is ratably connected to the fixed floor section of the core structure of the core structure around a first horizontal axis; and a first wall section is ratably connected to the first floor section around a second horizontal rotational axis.

24. The foldable building unit of Claim 22, wherein, in completely folded

configuration of the foldable building unit, the first floor section and the first wall section are folded between the core structure and the wall assembly.

25. The foldable building unit of any one of claims 1-24, wherein a first floor section is ratably connected to the fixed floor section of the core structure around a first horizontal axis; a first wall section is ratably connected to the first floor section around a second horizontal axis; a second f oor section is ratably connected to the fixed floor section of the core structure around a third horizontal axis; and a second wall section is ratably connected to the second floor section around a fourth horizontal axis.

26. The foldable building unit of any one of claims 1-25, wherein the wall

assembly is an interior wall assembly and, in completely unfolded configuration of the foldable building unit, the foldable building unit comprises

a first, adjacent floor section on a first side of the interior wall assembly and a second, adjacent floor section on a second side of the interior wall assembly, the second side being opposite the first side.

27. The foldable building unit of any one of claims 1-26, wherein the wall

a first, adjacent floor section on a first side of the interior wall assembly and a second, adjacent floor section on a second side of the interior wall assembly, the second side being opposite the first side; and

a first wall section foldably connected to the first floor section and a second wall section foldably connected to the second floor section, wherein the first wall section and the second wall section, each, provide an outside surface of the foldable building unit in completely unfolded configuration.

28. The foldable building unit of any one of claims 1-26, wherein the wall assembly is an interior wall assembly and, in completely unfolded configuration of the foldable building unit, the foldable building unit comprises

a first, adjacent floor section on a first side of the interior wall assembly and a second, adjacent floor section on a second side of the interior wall assembly, the second side being opposite the first side;

a first wall section foldably connected to the first floor section and a second wall section foldably connected to the second floor section, wherein the first wall section and the second wall section, each, provide an outside surface of the foldable building unit in completely unfolded configuration; wherein the interior wall assembly, in final unfolded configuration, is one interior wall; the interior wall has a bottom part positioned between the first and second floor sections, and the interior wall has a side part positioned between the first and second wall sections.

29. A method for constructing a building comprising

(1) placing a foldable building unit of any one of claims 1 to 28 on a foundation;

(2) rotably unfolding, around a vertical rotational axis, the wall assembly connected to the core structure from a folded configuration of the wall assembly, in which the foldably connected floor section is folded between the core structure and the wall assembly, to an unfolded configuration of the wall assembly, in which the foldably connected fioor section is no longer hindered by the wall assembly to rotably unfold around a first horizontal axis; and

(3) rotably unfolding, around the first horizontal axis, the foldably connected floor section from a folded configuration, in which the first floor section is in a vertical position, to an unfolded configuration, in which the first floor section is in a horizontal position.

30. The method of claim 29, wherein the wall assembly is an interior wall

assembly, the method further comprising:

(4) rotably, around a second horizontal axis, unfolding a second floor section from a folded configuration, in which the second floor section is in a vertical position, to an unfolded configuration, in which the second floor section is in a horizontal position, wherein the first and second floor section in unfolded configuration are on opposite sides of the interior wall assembly.

31. The method of claim 30, further comprising:

(5) rotably, around a third horizontal axis, unfolding a first wall section connected to the first floor section; and

(6) rotably, around a fourth horizontal axis, unfolding a second wall section foldably connected to the second floor section.

32. The method of any one of claims 29-31, further comprising installing

separate wall sections with wall and/or floor sections of the unfolded building unit to complete an exterior wall of the unfolded building unit, and installing at least one roof section to form a complete roof.

33. The method of any one of claims 29-32, further comprising removing the wall assembly from a cavity provided, partly or completely, by the first floor section.

34. A building comprising a plurality of foldable building units, independently, of any one of claims 1-33.

35. The building of claim 34, wherein at least one of the foldable building units has a wall assembly which is an interior wall assembly, and floor of one building unit is adjacent to a first side of the interior wall assembly, and floor of another building unit is adjacent to a second side of the interior wall assembly, the first side being opposite to the second side.