Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
  • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
  • E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
  • E04B1/34321—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by panels
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/38—Connections for building structures in general
  • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
  • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
  • E04B1/6116—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by locking means on lateral surfaces
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
  • E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
  • E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
  • E04C2/48—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose as high as or higher than the room, i.e. having provisions concerning the connection with at least two floors
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/38—Connections for building structures in general
  • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
  • E04B2001/6195—Connections for building structures in general of slab-shaped building elements with each other the slabs being connected at an angle, e.g. forming a corner
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
  • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
  • F16B5/02—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening members using screw-thread

Definitions

• the inventions herein relate to structures, such as dwellings and other buildings for residential occupancy, commercial occupancy and/or material storage, and to components for such structures.
• stick-built construction In the field of residential housing, the traditional technique for building homes is referred to as “stick-built” construction, where a builder constructs housing at the intended location using in substantial part raw materials such as wooden boards, plywood panels, and steel columns. The materials are assembled piece by piece over a previously prepared portion of ground, for example, a poured concrete slab or a poured concrete or cinder block foundation.
• the present inventions describe advancements in the design of appurtenances for building structures, particularly for the wall components of such structures.
• the present inventions are directed to a toe screw housing for securing abutting enclosure components together.
• the toe screw housing comprises a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face.
• a toe screw well joined to and extending away from the interior face of the bearing plate, which includes a fastener shelf, and there is provided a toe screw support that is joined to the interior face of the toe screw housing, and which is also joined to and extending away from the fastener shelf.
• the toe screw support distal from the fastener shelf includes a planar support surface oriented perpendicular to the interior face.
• a fastener bore passes through the fastener shelf, the toe screw support and the support surface, and is inclined at a non-perpendicular second angle relative to the interior face of the bearing plate.
• the present inventions are directed to a baseboard for masking a toe screw bearing plate that has a beveled upper edge.
• the baseboard comprises a planar elongate member having an elongate interior face, an elongate top edge and an elongate bottom edge.
• An elongate hook ledge is joined to the top edge of the base board to form a wedge-shaped angled slot that is oriented to be open in the direction of the bottom edge, with the wedge-shaped angled slot configured to be positioned over the beveled upper edge of the bearing plate.
• an elongate linear first step positioned on the interior face below the angled slot to form an elongate first recess on the interior face configured to receive the toe screw bearing plate
• an elongate second step positioned on the interior face below the elongate first step to form an elongate second recess on the interior face.
• Figure 1 is a perspective view of a structure prepared in accordance with the present inventions.
• Figure 2 is a top schematic view of the structure shown in Figure 1.
• Figure 3 is an end view of a shipping module from which is formed the structure shown in Figure 1.
• Figures 4 and 5 are partial cutaway views of a structure in accordance with the present inventions, depicting in greater detail aspects of the roof, wall and floor components.
• Figure 6 is a schematic perspective view depicting the exterior edge reinforcement for a wall component in accordance with the present inventions.
• Figure 7 is an exploded cross-sectional view of a multi-layered, laminate design for use in the enclosure components of the present inventions.
• Figure 8A is a front perspective view of a toe screw housing in accordance with the present inventions
• Figure 8B is a rear perspective view (looking upward) of a toe screw housing in accordance with the present inventions
• Figure 8C is a side view of a toe screw housing in accordance with the present inventions.
• Figures 9A, 9B and 9C are respectively front perspective, rear perspective and side views of an interior baseboard in accordance with the present inventions.
• Figure 10A is a side section view depicting a toe screw housing and an interior baseboard portion for a wall component in accordance with the present inventions
• Figure 10B is a side section view depicting a junction between a wall portion and a floor portion secured by a fastener inserted through a toe screw housing
• Figure IOC is a perspective cutaway view of representative placements of toe screw housings in accordance with the present inventions.
• Figures 11A, 1 IB and 11C are respectively perspective, top and side cutaway views of a fixed space portion of a structure in accordance with the present inventions.
• FIG. 1 An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in Figures 1 through 5.
• structure 150 When fully unfolded, as exemplified by Figure 1, structure 150 has a rectangular shape made of three types of generally planar and rectangular enclosure components 155, the three types of enclosure components 155 consisting of a wall component 200, a floor component 300, and a roof component 400.
• the perimeter of structure 150 is defined by first longitudinal edge 106, first transverse edge 108, second longitudinal edge 116 and second transverse edge 110.
• first longitudinal edge 106 and second longitudinal edge 116 may be referred to as the “longitudinal” direction
• a direction parallel to first transverse edge 108 and second transverse edge 110 may be referred to as the “transverse” direction
• a direction parallel to the vertical direction in Figure 1 may be referred to as the “vertical” direction.
• Structure 150 as shown has one floor component 300, one roof component 400 and four wall components 200; although it should be understood that the present inventions are applicable to structures having other configurations as well.
• Enclosure components 155 can be fabricated and dimensioned as described herein and positioned together to form a shipping module 100, shown end-on in Figure 3.
• the enclosure components 155 are dimensioned so that the shipping module 100 is within U.S. federal highway dimensional restrictions.
• shipping module 100 can be transported over a limited access highway more easily, and with appropriate trailering equipment, transported without the need for oversize permits.
• the basic components of structure 150 can be manufactured in a factory, positioned together to form the shipping module 100, and the modules 100 can be transported to the desired site for the structure, where they can be readily assembled, as described herein.
• the enclosure components 155 of the present invention include a number of shared design features that are described below.
• Enclosure components 155 can be fabricated using a multi-layered, laminate design.
• a particular laminate design that can be used to fabricate enclosure components 155 comprises a first structural layer 210, a foam panel layer 213, a second structural layer 215 and a protective layer 218, as shown in Figure 7 and described further below.
• first structural layer 210 is provided in the embodiment of enclosure component 155 that is depicted in Figure 7.
• First structural layer 210 in the embodiment shown comprises a sheet metal layer 205, which can be for example galvanized steel or aluminum.
• Sheet metal layer 205 is made from a plurality of generally planar rectangular metal sheets 206 positioned adjacent to each other to generally cover the full area of the intended enclosure component 155.
• a foam panel layer 213, comprising a plurality of generally planar rectangular foam panels 214 collectively presenting a first face 211 and a second opposing face 212.
• Foam panels 214 are made for example of expanded polystyrene (EPS) foam. A number of these foam panels 214 are positioned adjacent to each other and superposed first face-down on first structural layer 210 to generally cover the full area of the intended enclosure component 155.
• the foam panels 214 of foam panel layer 213 preferably are fastened to first structural layer 210 using a suitable adhesive, preferably a polyurethane based construction adhesive.
• Second structural layer 215 in the embodiment shown comprises a sheet metal layer 216, which can be for example galvanized steel or aluminum.
• Sheet metal layer 216 is made from a plurality of generally planar rectangular metal sheets 217 positioned adjacent to each other and superposed first face-down on the second opposing face of foam panel layer 213 to generally cover the full area of the intended enclosure component 155.
• the metal sheets 217 of second structural layer 215 preferably are fastened to foam panel layer 213 using a suitable adhesive, preferably a polyurethane based construction adhesive.
• a protective layer 218, having a first face that is positioned on the second opposing face of second structural layer 215 (the face distal from foam panel layer 213), and also having a second opposing face.
• Optional protective layer 218 in the embodiment shown comprises a plurality of rectangular structural building panels 219 principally comprising an inorganic composition of relatively high strength, such as magnesium oxide (MgO).
• MgO magnesium oxide
• the structural building panels 219 are positioned adjacent to each other and superposed first face-down on the second opposing face of second structural layer 215 to generally cover the full area of the intended enclosure component 155.
• the building panels 219 of protective layer 218 preferably are fastened to second structural layer 215 using a suitable adhesive, preferably a polyurethane based construction adhesive.
• a suitable adhesive preferably a polyurethane based construction adhesive.
• Protective layer 218 can be used if desired to impart a degree of fire resistance to the enclosure component 155, as well as to provide a pleasing texture and/or feel.
• Nonprovisional Patent Application No. 16/786,130 entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures,” filed on February 10, 2020 and now issued as U.S. Patent No. 11,118,344.
• the contents of that U.S. Nonprovisional Patent Application No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures” and filed on February 10, 2020 are incorporated by reference as if fully set forth herein, particularly including the multi-layered, laminate designs described for example at 3 ⁇ 4 0034-57 and depicted in Figures 4A-4D thereof.
• each enclosure component 155 i.e., the edges that define the perimeter of enclosure component 155) can be provided with exterior edge reinforcement, as desired.
• Exterior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the exterior edges of enclosure components 155.
• Exterior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the exterior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.
• Enclosure components 155 in certain instances are partitioned into enclosure component portions to facilitate forming a compact shipping module 100.
• any exterior edge reinforcement on the exterior edges defining the perimeter of the enclosure component is segmented as necessary between or among the portions.
• the enclosure component portions can be joined by hinge structures or mechanisms to permit the enclosure component portions to be “folded” and thereby contribute to forming a compact shipping module 100.
• An enclosure component 155 partitioned into enclosure component portions will have interior edges. There will be two adjacent interior edges for each adjacent pair of enclosure component portions. Such interior edges can be provided with interior edge reinforcement. Similar to exterior edge reinforcement, such interior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the interior edges of enclosure components 155. Interior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the interior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.
• enclosure components 155 it is necessary to transfer the loads imposed on their surfaces to their exterior edges, where those loads can be transferred either to or through adjoining walls, or to the building foundation.
• loads include the weight of equipment, furniture and people borne by their surfaces, as well as vertical seismic loads.
• loads include those arising from meteorological conditions (hurricanes, tornadoes, etc.) and human action (vehicle and other object impacts).
• Structure 150 comprises a number of wall, floor and roof components with abutting or exposed exterior edges, as well as a number of partitioned wall, floor and roof components with interior edges.
• sealing structures can be utilized, with the objective to limit or prevent the ingress of rain water, noise and outside air across these exterior and interior edges into the interior of structure 150.
• wall component 200 floor component 300, and roof component 400 are provided in the sections following.
• structure 150 will utilize four wall components 200, with each wall component 200 corresponding to an entire wall of structure 150.
• Wall component 200 has a generally rectangular perimeter. As shown in Figure 1, wall components 200 have plural apertures, specifically a door aperture 202, which has a door frame and door assembly, and plural window apertures 204, each of which has a window frame and a window assembly.
• the height and length of wall components 200 can vary in accordance with design preference, subject as desired to the dimensional restrictions applicable to transport, described above.
• structure 150 is fashioned with all sides of equal length; accordingly, its first and second longitudinal edges 106 and 116, and its first and second transverse edges 108 and 110, are all of equal length. It should be understood however, that the inventions described herein are applicable to structures having other dimensions, such as where two opposing wall components 200 are longer than the other two opposing wall components 200.
• wall components 200 of the present inventions can utilize a multi-layered, laminate design.
• wall component 200 utilizes the multi-layered, laminate design shown in Figure 7 employing these particular elements: sheet metal layer 205 of first structural layer 210 is 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick, the foam panels 214 of foam panel layer 213 are EPS foam approximately 5.68 inches thick, the sheet metal layer 216 of second structural layer 215 is 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick, and the building panels 219 of protective layer 218 are MgO board approximately 0.25 inch (6 mm) thick.
• each wall component 200 is generally provided with exterior edge reinforcement.
• the exterior edge reinforcement for wall component 200 is a floor plate 220 along the bottom horizontal edge, a ceiling plate 240 along the top horizontal edge and two end pieces 270 respectively fastened at each vertical edge of wall component 200.
• exterior edge reinforcement provides regions for fastening like regions of abutting wall components 200, roof component 400 and floor component 300, in addition to protecting the exterior edges of foam panel material.
• the exterior edge reinforcement for wall component 200 provided by floor plate 220, ceiling plate 240, and end pieces 270 is fabricated from laminated strand lumber board 5.625” deep and 1.5” thick.
• structure 150 has two opposing wall components 200, where one of the two opposing wall components 200 comprises first wall portion 200s- 1 and second wall portion 200s-2, and the other of the two opposing wall components 200 comprises third wall portion 200s-3 and fourth wall portion 200s-4.
• Each of wall portions 200s- 1, 200s-2, 200s-3 and 200s-4 has a generally rectangular planar structure.
• the interior vertical edge 192-1 of wall portion 200s- 1 is proximate to a respective interior vertical edge 192-2 of wall portion 200s-2
• the interior vertical edge 194-3 of wall portion 200s-3 is proximate a respective interior vertical wall edge 194-4 of wall portion 200s-4.
• Interior edge reinforcement can be provided at any one or more of vertical edges 192-1, 192-2, 194-3 and 194-4.
• the interior edge reinforcement provided at vertical edges 192-1, 192-2, 194-3 and 194-4 is fabricated from laminated strand lumber board 5.625” deep and 1.5” thick.
• first wall portion 200s- 1 is fixed in position on floor portion 300a proximate to first transverse edge 108
• third wall portion 200s-3 is fixed in position on floor portion 300a, opposite first wall portion 200s- 1 and proximate to second transverse edge 110.
• First wall portion 200s- 1 is joined to second wall portion 200s-2 with a hinge structure that permits wall portion 200s-2 to pivot about vertical axis 192 between a folded position and an unfolded position
• third wall portion 200s-3 is joined to fourth wall portion 200s-4 with a hinge structure to permit fourth wall portion 200s-4 to pivot about vertical axis 194 between a folded position and an unfolded position.
• first wall portion 200s- 1 is longer than third wall portion 200s-3 by a distance approximately equal to the thickness of wall component 200
• second wall portion 200s-2 is shorter than fourth wall portion 200s-4 by a distance approximately equal to the thickness of wall component 200.
• wall portion 200s- 1 and wall portion 200s-3 are each shorter in length (the dimension in the transverse direction) than the dimension of floor portion 300a in the transverse direction. Dimensioning the lengths of wall portions 200s- 1, 200s-2, 200s-3 and 200s-4 in this manner permits wall portions 200s- 2 and 200s-4 to nest against each other in an overlapping relationship when in an inwardly folded position.
• Figure 2 depicts wall portions 200s-2 and 200s-4 both in their unfolded positions, where they are labelled 200s-2u and 200s4-u respectively, and Figure 2 also depicts wall portions 200s-2 and 200s-4 both in their inwardly folded positions, where they are labelled 200s-2f and 200s4-f respectively.
• wall portions 200s-2 and 200s-4 are in their inwardly folded positions (200s-2f and 200s-4f), they facilitate forming a compact shipping module.
• wall portion 200s-2 When wall portion 200s-2 is in its unfolded position (200s-2u), it forms with wall portion 200s- 1 a wall component 200 proximate first transverse edge 108, and when wall portion 200s-4 is in its unfolded position (200s-4u), it forms with wall portion 200s-3 a wall component 200 proximate second transverse edge
• the hinge structures referenced for securing first wall portion 200s- 1 to second wall portion 200s-2, and third wall portion 200s-3 to fourth wall portion 200s-4, can be surface mounted or recessed, and of a temporary or permanent nature.
• the provision of interior edge reinforcement, as described above, can provide a region for securing hinge structures.
• Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material.
• the remaining two wall components 200 proximate first and second longitudinal edges 106 and 116 do not comprise plural wall portions, but rather each is a single piece structure.
• one of these wall components 200 which is sometimes denominated 200P in this disclosure, and which is located on floor portion 300b proximate first longitudinal edge 106, is pivotally secured to floor portion 300b to permit wall component 200P to pivot about horizontal axis 105 shown in Figure 3 from a folded position to an unfolded position. Pivotally securing wall component 200P also facilitates forming a compact shipping module 100.
• the remaining wall component 200 is rigidly secured on floor portion 300a proximate second longitudinal edge 116 and abutting the vertical edges of first wall portion 200s- 1 and third wall portion 200s-3 proximate to second longitudinal edge 116, as shown in Figure 2.
• the hinge structures described above, for securing wall component 200P to floor portion 300b can be surface mounted or recessed, and of a temporary or permanent nature.
• the provision of exterior edge reinforcement, as described above, can provide a region for securing hinge structures.
• Suitable hinge structures can be fabricated for example of metal, plastic, leather, ferrous or non-ferrous material.
• FIGS. 8A-8C depict a toe screw housing 288, whose principal components comprise a bearing plate 292, a toe screw well 289 and a toe screw support 221.
• Bearing plate 292 is a planar plate of a select thickness having a rectangular perimeter, and includes an exterior face 293, an opposed interior face 294 and a top, bevel edge 297.
• Toe screw well 289 comprises a semi- cylindrical wall 298 having an axial centerline 198, shown in Figure 8C, which is oriented at an angle cpi from a line normal to the interior face 294 of bearing plate 292.
• Angle cpi can be in the range of forty-five (45°) to seventy (70°) degrees, such as sixty (60°) degrees.
• the exterior face 293 of bearing plate 292 defines an aperture that renders the interior volume of toe screw well 289 accessible from the exterior face side of toe screw well 289.
• An upper portion of semi-cylindrical wall 298 is angularly sectioned, for example at an angle of ninety degrees (90°) minus (pi, relative to axial centerline 198, for example in the range of forty-five (45°) to twenty (20°) degrees, such as thirty (30°) degrees, with the upper portion so sectioned joined to interior face 294.
• a lower portion of semi-cylindrical wall 298 is further sectioned parallel to axial centerline 198, with each of the resultant two axially-oriented edges joined to a respective triangular gusset 299.
• the two gussets 229 are spatially opposed and joined to the interior face 294 of bearing plate 292.
• Toe screw well 289 also includes a fastener shelf 239, visible in Figure 8A, which is joined to semi- cylindrical wall 298 and each of the two gussets 299.
• the interior volume of toe screw well 289 which is defined by fastener shelf 239, gussets 299 and semi-cylindrical wall 298, forms a recess within toe screw well 289 for receiving a fastener head.
• Fastener shelf 239 has a planar upper face that is perpendicularly oriented to the axial centerline 198 of semi- cylindrical surface 298, and a planar opposed lower face that is perpendicularly oriented to the axial centerline 198 of semi-cylindrical surface 298. It should be noted that the upper face of fastener shelf 239 will correspondingly be oriented at angle cpi relative to interior face 294 and exterior face 293.
• Toe screw support 221 comprises a semi-cylindrical solid 222 and a triangular wedge 223.
• Semi- cylindrical solid 222 has an axial centerline 197, shown in Figure 8C, which is oriented at an angle cpi from a line normal to the interior face 294 of bearing plate 292.
• Angle cpi can be in the range of forty-five (45°) to seventy (70°) degrees, such as sixty (60°) degrees, and preferably cpi equals cpi.
• Centerlines 197 and 198 can be, but need not be, co-linear.
• the upper portion of semi-cylindrical solid 222 is sectioned normal to axial centerline 197, with the sectioned portion joined to the lower face of fastener shelf 239, and is further sectioned parallel to axial centerline 197 and joined to triangular wedge 223.
• the upper surface of wedge 223 is joined to the lower face of fastener shelf 239, and wedge 223 is further joined at its narrow end to the interior face 294 of bearing plate 292.
• the diameter of semi-cylindrical solid 222 is less than the diameter of semi-cylindrical wall 298, in the embodiment shown in Figures 8A-8C.
• Toe screw support 221 also includes a support surface 224 defined by the lower surfaces of semi-cylindrical solid 222 and wedge 223. Support surface 224 is perpendicularly oriented to the interior face 294 of bearing plate 292. A groove 199 is cut into the planar lower surface of support surface 224. Groove 199 is oriented parallel to the interior face 294 of bearing plate 292, and, in the embodiment shown in the figures, is spaced from interior face 294 a distance approximately equal to the thickness of protective layer 218.
• a fastener bore 225 passes through fastener shelf 239 and toe screw support 221, with an exit orifice in support surface 224, thereby forming a passage through toe screw support 221 for a fastener, the head of which can be positioned against the upper face of fastener shelf 239.
• the axial centerline of fastener bore 225 is co-linear with the axial centerline 197 of semi-cylindrical wall 222, so that the axial centerline of fastener bore 225 is not perpendicular to the exterior face 293 of bearing plate 292, but rather is oriented at angle cpi from a line normal to the exterior face 293 of bearing plate 292.
• Bevel edge 297 of toe screw housing 288 forms an angle with exterior face 293 to provide a sloped bevel surface between the end of bevel edge 297 and interior face 294 of bearing plate 292. Accordingly, angle is not perpendicular to the exterior face 293 of bearing plate 292, but rather is an acute angle, such as forty-five degrees (45°) or less, and in particular twenty degrees (20°).
• Figures 9A-9C depict an interior baseboard 140.
• Interior baseboard 140 is a planar elongate member with a planar elongate exterior face 141, a planar elongate interior face 142, an elongate top edge 143 and an elongate bottom edge 144.
• An elongate hook ledge 145 is joined along the top edge 143 of interior baseboard 140 and forms a downward facing wedge-shaped angled slot 146 that has an interior angle qn, shown in Figure 9C, which is preferably the same as angle cp3 of bevel edge 297, or nearly so.
• Interior face 142 has an elongate linear first step 147 positioned below angled slot 146, so as to define an elongate bearing plate recess 148 between angled slot 146 and first step 147 sufficiently wide to receive bearing plate 292. Positioned below first step 147, interior face 142 has an elongate linear second step 137 that extends a distance from bottom edge 144, so as to define a fastening recess 138 between first step 147 and second step 138.
• each toe screw housing 288 is positioned so that the support surface 224 of its toe screw support 221 rests upon the floor plate 220 of the wall component 200.
• Select portions of the foam panel layer 213, sheet metal layer 216 and protective layer 218 are removed to provide a space to receive the toe screw well 289 and toe screw support 221 of the toe screw housing 288, and so that the interior face 294 of bearing plate 292 of the toe screw housing 288 lies against protective layer 218.
• groove 199 can engage the edge of sheet metal layer 216 immediately below the removed portion thereof, as shown in Figure 10A.
• Plural toe screw housings 288 can be utilized to fasten both partitioned and unpartitioned wall components 200 to floor component 300 (described below).
• toe screw housings 288 are shown being utilized in connection with both wall portion 200s-4 and wall component 200P.
• a fastener such as a SIP screw 136 can be inserted into fastener bore 225, as illustrated in Figure 10A, and driven into the exterior edge reinforcement of both the wall component 200 and the underlying floor component 300, specifically floor plate 220 and footing beam 320 respectively, as shown in Figure 10B, to fasten the wall component 200 to the floor component 300.
• Plural toe screw housings 288 can also be utilized to fasten each of fixed wall component 200R, fixed wall portion 200s- 1, fixed wall portion 200s-3 and pivoting wall portion 200s-2 to floor component 300.
• the fastening operation just described can be undertaken during factory fabrication of fixed space portion 102, described further below.
• toe screw housings 288 In using toe screw housings 288 to fasten wall component 200P to floor section 300b, it can be seen in Figure 10B that one or more screws 136 will also pass through two sealing structures, wall end cap 246 and floor top plate 252, which are present at the junction of wall component 200P and floor portion 300b.
• PCT/US21/56415 entitled “Enclosure Component Sealing Systems,” filed on October 25, 2021 and having the same inventors as this disclosure, are incorporated by reference as if fully set forth herein, particularly including the wall end cap 246 and floor top plate 252 described for example at 3 ⁇ 4 0092, 0097-0101 and 0112-0120, and in connection with Figures 12 and 15, of that application.
• one or more screws 136 will also pass through sealing structures that are present at the junction of pivoting wall portion 200s-2 in its unfolded position and floor portions 300a/300b, and at the junction of pivoting wall portion 200s-4 in its unfolded position and floor portions 300a/300b.
• these sealing structures namely wall end interlock A 262 (not shown) and floor top interlock 261 (not shown), differ from wall end cap 246 and floor top plate 252, in that they are designed to permit the lateral movement of wall portions 200s-2 and 200s-4 relative to floor portions 300a and 300b.
• the housings can be masked from view by placing an interior baseboard 140 of an appropriate length over the toe screw housings, as shown in Figure 10A.
• the size of interior baseboard 288 can be adjusted prior to installation to accommodate flooring finishes of different types.
• the interior face 142 is provided with a first elongate linear notch 149 (see Figures 9B, 9C) above bottom edge 144 a sufficient distance to indicate the cut line for accommodating thin flooring, such as floor tiles, and a second elongate linear notch 139 (see Figures 9B, 9C), above notch 149 a sufficient distance to indicate the cut line for accommodating thicker flooring, such as hardwood flooring.
• the hook ledge 145 of interior baseboard 140 engages the bevel edge 297 of the toe screw housings 288 positioned along the bottom of the wall component 200, which thus facilitates the rapid and accurate placement of interior baseboard 140.
• the interior baseboard 140 can be secured in place by providing for example hook-and-loop fasteners, or adhesive material, in the fastening recess 138 of the interior baseboard 140.
• Toe screw housings 288 and interior baseboard 140 can be made from aluminum, plastics and the like. It is preferred to fabricate the toe screw housing 288 and interior baseboard 140 from foamed polyvinyl chloride (PVC), particularly Celuka foamed PVC.
• PVC polyvinyl chloride
• structure 150 will utilize one floor component 300; thus floor component 300 generally is the full floor of structure 150.
• Floor component 300 has a generally rectangular perimeter.
• Figures 4 and 5 depict edge-on views of floor component 300 in accordance with the present inventions.
• the perimeter of floor component 300 is defined by first longitudinal floor edge 117, first transverse floor edge 120, second longitudinal floor edge 119 and second transverse floor edge 118.
• first longitudinal floor edge 117, (b) first transverse floor edge 120, (c) second longitudinal floor edge 119 and (d) second transverse floor edge 118 generally coincide with (i.e., underlie) (w) first longitudinal edge 106, (x) first transverse edge 108, (y) second longitudinal edge 116 and (z) second transverse edge 110, respectively, of structure 150.
• the length and width of floor component 300 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in Figures 2, 4 and 5, floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).
• Floor component 300 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which floor component 300 may be subject. It is preferred that floor component 300 utilize a multi-layered, laminate design, such as that described in connection with Figure 7.
• the bottom-most surface of floor component 300 comprises sheet metal layer 205 of first structural layer 210, with sheet metal layer 205 being 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick.
• foam panels 214 are EPS foam for example approximately 7.125 inches thick.
• sheet metal layer 216 of second structural layer 215 Above foam panel layer 213 there is provided sheet metal layer 216 of second structural layer 215, with sheet metal layer 216 being 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick. Above sheet metal layer 216 of second structural layer 215, there are provided building panels 219 of protective layer 218, with building panels 219 being MgO board approximately 0.25 inch (6 mm) thick.
• each floor component 300 is generally provided with exterior edge reinforcement.
• a first footing beam 320 (visible edge-on in Figure 4) is positioned at the first longitudinal floor edge 117 of floor component 300
• a second footing beam 320 (visible edge-on in Figure 5) is positioned at the second transverse floor edge 118 of floor component 300
• a third footing beam 320 (visible edge-on in Figure 5) is positioned at the first transverse floor edge 120 of floor component 300
• a fourth footing beam 320 (visible edge-on in Figure 4) is positioned at the second longitudinal floor edge 119 of floor component 300.
• the exterior edge reinforcement provided by footing beams 320 assists in resisting vertical loads and transferring such loads to any roof component 400 thereunder and then to underlying wall components 200, and/or to the foundation of the finished structure 150, in addition to protecting the edges of foam panel material.
• the exterior edge reinforcement provided by footing beams 420 of floor component 300 is fabricated from laminated strand lumber board 7.125” deep and 1.5” thick.
• the floor component 300 is partitioned into floor portion 300a and floor portion 300b.
• Figure 2 shows flow portions 300a and 300b in plan view
• Figure 4 shows floor portions 400a and 400b in section view, edge-on.
• Each of the floor portions 300a and 300b is a planar generally rectangular structure, with floor portion 300a adjoining floor portion 300b. Interior edge 301a of floor portion 300a abuts interior edge 301b of floor portion 300b, as shown in Figure 4.
• a reinforcing board 307 is positioned in floor portion 300a adjacent interior edge 301a, and a reinforcing board is positioned in floor portion 300b adjacent interior edge 301b.
• the interior edge reinforcement provided by reinforcing boards 307 is made of laminated strand lumber laminated strand lumber board 7.125” deep and 1.5” thick.
• floor portion 300a is fixed in position relative to first wall portion 200s- 1, third wall portion 200s-3 and wall component 200s-R.
• Floor portion 300a is joined with hinge structures to floor portion 300b, so as to permit floor portion 300b to pivot through approximately ninety degrees (90°) of arc about a horizontal axis 305, located proximate the top surface of floor component 300, between a fully folded position, where floor portion 300b is vertically oriented as shown in Figure 3, and the fully unfolded position shown in Figures 2 and 4, where floor portion 300b is horizontally oriented and co-planar with floor portion 300a.
• 90° ninety degrees
• structure 150 will utilize one roof component 400; thus roof component 400 generally is the full roof of structure 150.
• Roof component 400 has a generally rectangular perimeter.
• Figures 1, 4 and 5 depict roof component 400 in accordance with the present inventions.
• the perimeter of roof component 400 is defined by first longitudinal roof edge 406, first transverse roof edge 408, second longitudinal roof edge 416 and second transverse roof edge 410.
• first longitudinal roof edge 406, (b) first transverse roof edge 408, (c) second longitudinal roof edge 416 and (d) second transverse roof edge 410 of roof component 400 generally coincide with (i.e., overlie) (w) first longitudinal edge 106, (x) first transverse edge 108, (y) second longitudinal edge 116 and (z) second transverse edge 110, respectively, of structure 150.
• roof component 400 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in Figures 1, 4 and 5, the length and width of roof component 400 approximates the length and width of floor component 300.
• roof component 400 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which roof component 400 may be subject. It is preferred that roof component 400 utilize a multi-layered, laminate design, such as that described in connection with Figure 7.
• the top-most surface of roof component 400 comprises sheet metal layer 205 of first structural layer 210, with sheet metal layer 205 being 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick.
• foam panels 214 of foam panel layer 213 with foam panels 214 in the embodiment shown in Figures 4 and 5 being EPS foam for example approximately 7.125 inches thick.
• sheet metal layer 216 of second structural layer 215 Below foam panel layer 213 there is provided sheet metal layer 216 of second structural layer 215, with sheet metal layer 216 being 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick. Below sheet metal layer 216 of second structural layer 215, there are provided building panels 219 of protective layer 218, with building panels 219 being MgO board approximately 0.25 inch (6 mm) thick.
• the perimeter of roof component 400 is generally provided with exterior edge reinforcement.
• a first shoulder beam 435 (visible edge-on in Figure 4) is positioned at the first longitudinal roof edge 406 of roof component 400
• a second shoulder beam 435 (visible edge-on in Figure 5) is positioned at the first transverse roof edge 408 of roof component 400
• a third shoulder beam 435 (visible edge-on in Figure 5) is positioned at the second transverse roof edge 410 of roof component 400
• a fourth shoulder beam 435 (visible edge-on in Figure 4) is positioned at the second longitudinal roof edge 416 of roof component 400.
• the exterior edge reinforcement provided by shoulder beams 435 assists in resisting vertical loads and transferring such loads to lower floors through underlying wall components 200 supporting roof component 400, and then to the foundation of the structure 150.
• Such exterior edge reinforcement can also provide a region for fastening like regions of abutting enclosure components 155 (underlying and any overlying).
• Shoulder beams 435 of roof component 400 can be fabricated from laminated strand lumber board 7.125” deep and 1.5” thick.
• roof component 400 of structure 150 is partitioned into roof portions 400a,
• Figure 1 shows roof portions 400a, 400b and 400c in perspective view
• Figure 4 shows roof portions 400a, 400b and 400c in section view, edge-on.
• Each of the roof portions 400a, 400b and 400c is a planar generally rectangular structure, with roof portion 400a adjoining roof portion 400b, and roof portion 400b adjoining roof portion 400c.
• Interior edge 412c of roof component 400c abuts a first interior edge 412b of roof component 400b, as shown in Figure 4.
• a reinforcing board 437 is positioned adjacent interior edge 412c, and a reinforcing board 437 is positioned against first interior edge 412b.
• Interior edge 412a of roof portion 400a abuts a second interior edge 412b of roof portion 400b, as shown in Figure 4.
• a reinforcing board 437 is positioned adjacent interior edge 412a, and a reinforcing board 437 is positioned against second interior edge 412b.
• the interior edge reinforcement provided by reinforcing boards 437 of roof component 400 is laminated strand lumber board 7.125” deep and 1.5” thick.
• roof portions 400a, 400b and 400c preferably are accordion folded (stacked), with roof component 400b stacked on top of roof component 400a, and roof component 400c stacked on top of the roof component 400b.
• roof portion 400a is fixed in position relative to first wall portion 200s- 1, third wall portion 200s-3 and wall component 200R.
• roof portion 400a is joined to roof portion 400b with hinge structures provided between interior edge 412a of roof portion 400a and second interior edge 412b of roof portion 400b.
• Such hinge structures are adapted to permit roof portion 400b to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405a, located proximate the top of roof component 400 and shown in Figure 4, between the roof fully folded position shown in Figure 3, where roof portion 400b lies stacked flat against roof portion 400a, and the fully unfolded position shown in Figure 4.
• roof portion 400b is joined to roof portion 400c with hinge structures provided between first interior edge 412b of roof portion 400b and interior edge 412c of roof portion 400c.
• Such hinge structures are adapted to permit roof portion 400c to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405b, located proximate the bottom of roof component 400 and shown in Figure 4, between the folded position shown in Figure 3, where roof portion 400c lies stacked flat against roof portion 400b (when roof portion 400b is positioned to lie flat against roof portion 400a), and the fully unfolded position shown in Figure 4.
• metal sheets 206 and 217 that can be used to form first structural layer 210 and second structural layer 215 respectively can be entirely flat and juxtaposed in a simple abutting relationship.
• metal sheets 206 and 217 can be provided with edge structures that facilitate placement of sheets and panels during manufacture.
• structure 150 includes a fixed space portion 102 defined by roof component 400a (shown in Figure 3), floor component 300a, wall component 200R, wall portion 200s- 1 and wall portion 200s-3. (Fixed space portion 102 is also shown edge-on in the shipping module 100 depicted in Figure 3). It is preferred that the fixed space portion 102 be fitted out during manufacture with internal components, such as kitchens, bathrooms, closets, storage areas, corridors, etc., so as to be in a relatively finished state prior to shipment of shipping module 100.
• partition walls 126 and 127 each can comprise a foam panel layer, for example three inches (3”) thick, with building panels such as magnesium oxide (MgO) board approximately 0.25 inch (6 mm) thick fastened to each face of the foam panel using a suitable adhesive, preferably a polyurethane based construction adhesive.
• MgO magnesium oxide
• a first vertical edge of longitudinal partition wall 126 abuts wall portion 200s- 1, and a first vertical edge of transverse partition wall 127 abuts wall component 200R.
• the second vertical edge of transverse wall portion 127 abuts the longitudinal partition wall 126 proximate to the latter’s second vertical edge, such that partition walls 126 and 127, with wall component 200R and wall portion 200s- 1, form a rectangular enclosed area that, in the embodiment shown in Figures 2 and 1 lA-11C, is a bath room 128.
• bath room 128 is fitted out during manufacture to include a shower enclosure, a toilet and a wash sink.
• the open area between transverse partition wall 127 and wall portion 200s-3 in the embodiment shown in Figures 2 and 1 lA-11C is a kitchen area 129.
• kitchen area 129 is fitted out during manufacture to include cabinets, countertops and cooking facilities.
• wall components 200 are fitted during manufacture and prior to shipment with all necessary door and window assemblies, with the enclosure components 155 being pre-wired for electrical needs.
• Figure 2 shows a top schematic view of structure 150 shown in Figure 1, and includes a geometrical orthogonal grid for clarity of explaining the preferred dimensional relationships among its enclosure components 155.
• the basic length used for dimensioning is indicated as “E” in Figure 2; the orthogonal grid overlaid in Figure 2 is 8E long and 8E wide; notably, the entire structure 150 preferably is bounded by this 8E by 8E orthogonal grid.
• Roof portions 400a, 400b and 400c each can be identically dimensioned in the transverse direction.
• roof portion 400c can be dimensioned to be larger than either of roof portion 400a and roof portion 400b in the transverse direction to reduce the chances of binding during the unfolding of roof portions 400b, 400c.
• Further specifics on dimensioning roof portion 400c in the foregoing manner are described in U.S. Nonprovisional Application No. 17/569,962, entitled “Improved Folding Roof Component,” filed on January 6, 2022.
• friction-reducing components can be used to facilitate unfolding roof component 400, such as by positioning a first wheel caster at the leading edge of roof portion 400c proximate to the comer of roof portion 400c that is supported by wall portion 200s-2 as roof portion 400c is deployed, and by positioning a second similar wheel caster at the leading edge of roof portion 400c proximate to the comer of roof portion 400c that is supported by wall portion 200s-4 as roof portion 400c is deployed.
• the four wall components 200 are each approximately 8E long, and each of roof portions 400a and 400b is approximately 8E long and 2.5E wide. Roof portion 400c is approximately 8E long and 2.9E wide.
• each of floor components 300a and 300b is 8H long; whereas floor component 300a is just over 3E wide and floor component 300b is just under 5E wide.
• fourth wall portion 200s-4 is folded inward and positioned generally against fixed space portion 102
• second wall portion 200s-2 is folded inward and positioned generally against fourth wall portion 200s-4
• wall portions 200s-2 and 200s- 4 are respectively identified in Figure 2 as portions 200s-2f and 200s-4f when so folded and positioned.
• the three roof components 400a, 400b and 400c are shown unfolded in Figure 1 and shown folded (stacked) in Figure 3, with roof component 400b stacked on top of roof component 400a, and roof component 400c stacked on top of the roof component 400b.
• Wall component 200P shown in Figures 2 and 3, is pivotally secured to floor portion 300b at the location of axis 105, and is vertically positioned against the outside of wall portions 200s-2 and 200s-4.
• floor portion 300b is vertically positioned proximate fixed space portion 102, with wall component 200P pending from floor portion 300b between floor portion 300b and wall portions 200s-2 and 200s-4.
• shipping module 100 depicted in Figure 3 when dimensioned according to the relationships disclosed herein using an “E” dimension (see Figure 2) of approximately 28.625 inches (72.7 cm), and when its components are stacked and positioned as shown in Figure 3, has an overall length of approximately 19 feet (5.79 m), an overall width of approximately 8.5 feet (2.59 meters) and an overall height of approximately 12.7 feet (3.87 meters). These overall dimensions are less than a typical shipping container.
• Each of the wall, floor and roof components 200, 300 and 400, and/or the portions thereof, can be sheathed in protective film 177 during fabrication and prior to forming the shipping module 100.
• the entire shipping module 100 can be sheathed in a protective film.
• Such protective films can remain in place until after the shipping module 100 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.
• the shipping module 100 is shipped to the building site by appropriate transport means.
• One such transport means is disclosed in U.S. Nonprovisional Application No. 16/143,628, filed September 27, 2018 and now U.S. Patent No. 11,007,921, issued May 18, 2021; the contents of that U.S. Nonprovisional Application No. 16/143,628, filed September 27, 2018 are incorporated by reference as if fully set forth herein, particularly as found at paragraphs 0020-0035 and in Figures 1A-2D thereof.
• shipping module 100 can be shipped to the building site by means of a conventional truck trailer or a low bed trailer (also referred to as a lowboy trailer), and in the case of over-the- water shipments, by ship. Structure Deployment and Finishing
• shipping module 100 is positioned over its desired location, such as over a prepared foundation; for example, a poured concrete slab, a poured concrete or cinder block foundation, sleeper beams or concrete posts or columns.
• a prepared foundation for example, a poured concrete slab, a poured concrete or cinder block foundation, sleeper beams or concrete posts or columns.
• This can be accomplished by using a crane, either to lift shipping module 100 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 100, then moving the transport means from the desired location, and then lowering shipping module 100 to a rest state at the desired location.
• a crane either to lift shipping module 100 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 100, then moving the transport means from the desired location, and then lowering shipping module 100 to a rest state at the desired location.
• Particularly suitable equipment and techniques for facilitating the positioning of a shipping module 100 at the desired location are disclosed in U.
• a mobile crane can be used to assist in the deployment of certain of the enclosure components 155, specifically roof portions 400b and 400c, floor portion 300b, as well as the wall component 200P pivotally secured to floor portion 300b.
• the enclosure components 155 specifically roof portions 400b and 400c, floor portion 300b, as well as the wall component 200P pivotally secured to floor portion 300b.
• particularly suitable equipment and techniques for facilitating the deployment of enclosure components 155 are disclosed in U.S. Nonprovisional Patent Application No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on February 10, 2020, now U.S. Patent No. 11,220,816. The contents of that U.S. Nonprovisional Patent Application No.
• the enclosure components 155 are secured together to finish the structure 150 that is shown in Figure 1. If any temporary hinge structures have been utilized, then these temporary hinge structures can be removed if desired and the enclosure components 155 can be secured together. During or after unfolding and securing of the enclosure components 155, any remaining finishing operations are performed, such as addition of roofing material, and making hook-ups to electrical, fresh water and sewer lines to complete structure 150, as relevant here.
• a toe screw housing for securing abutting enclosure components together, comprising: a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face; a toe screw well joined to and extending away from the interior face and including a fastener shelf; a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate.
• Clause 2 The toe screw housing of clause 1, further including a groove formed in the support surface oriented parallel to the interior face.
• Clause 3 The toe screw housing of either of clause 1 or clause 2, wherein the second angle is in the range of forty-five degrees (45°) to seventy degrees (70°).
• Clause 4 The toe screw housing of any one of clause 1, 2 or 3, where the second angle is sixty degrees (60°).
• Clause 5. The toe screw housing of any one of clause 1, 2, 3 or 4, where the first angle is less than forty-five degrees (45°).
• Clause 6 The toe screw housing of any one of clause 1, 2, 3, 4 or 5, where the first angle is twenty degrees (20°).
• a baseboard for masking a toe screw bearing plate having a beveled upper edge comprising: a planar elongate member having an elongate interior face, an elongate top edge and an elongate bottom edge; an elongate hook ledge joined to the top edge of the base board forming a wedge- shaped angled slot that is oriented to be open in the direction of the bottom edge, the wedge- shaped angled slot configured to be positioned over the beveled upper edge of the bearing plate; an elongate linear first step positioned on the interior face below the angled slot to form an elongate first recess on the interior face configured to receive the toe screw bearing plate; and an elongate second step positioned on the interior face below the elongate first step to form an elongate second recess on the interior face.
• Clause 8 A baseboard as in clause 7, further comprising a first elongate linear notch in the second step a first select distance above the bottom edge.
• Clause 9 A baseboard as in either of clause 7 or clause 8, further comprising a second elongate linear notch in the second step a second select distance above the bottom edge that is greater than the first select distance.
• a system for securing abutting enclosure components together comprising:
• a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and
• a wall component comprising:
• each of the plurality of toe screw housings comprising:
• a folded building structure transportable to a site at which the folded building structure is to be erected comprising: a fixed space portion defined by (i) a first floor portion having an edge reinforcement along a first outside edge and an edge reinforcement segment along an adjacent second outside edge, (ii) a first wall component having an edge reinforcement along a first bottom edge positioned on the first floor portion proximate the first outside edge, and (iii) a planar fixed wall portion of a second wall component having an edge reinforcement segment along a second bottom edge positioned on the first floor portion proximate the second outside edge; a second floor portion vertically positioned in a second floor portion folded position opposite to the first wall component and pivotally connected to the first floor portion to permit the second floor portion to pivot, about a first horizontal axis relative to the first floor portion, from the second floor portion folded position to a second floor portion unfolded position, the second floor portion having an edge reinforcement along a third outside edge distal from the first horizontal axis and an edge reinforcement segment along an adjacent fourth outside edge
• a building comprising: an interior region defined by (i) a floor portion having an edge reinforcement along a first outside edge and an edge reinforcement segment along an adjacent second outside edge, (ii) a wall component having an edge reinforcement along a first bottom edge positioned on the first floor portion proximate the first outside edge, and (iii) a wall portion having an edge reinforcement segment along a second bottom edge positioned on the first floor portion proximate the second outside edge; a first plurality of toe screw housings having a spaced-apart relationship, each of the first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fasten
• Clause 18 The building of clause 17, further comprising a first interior partition wall abutting one of (i) the inside surface of the wall component and (ii) an inside surface of the wall portion, and extending perpendicularly therefrom.
• Clause 19 The building of clause 18, further comprising a second interior partition wall abutting the other of the inside surface of the wall component and the inside surface of the wall portion and extending perpendicularly therefrom to form a junction with the first interior partition wall and thereby define an enclosed interior space.
• Clause 20 The building of either of clause 18 or clause 19, wherein the first interior partition wall comprises:
• a second protective layer having a first face, an opposing second face, with the first face of the second protective layer being bonded to the opposing second face of the foam panel layer.
• a second protective layer having a first face, an opposing second face, with the first face of the second protective layer being bonded to the opposing second face of the foam panel layer.
• Clause 22 The building of either of clause 19 or clause 21, wherein the enclosed interior space includes one or more of a shower enclosure, a toilet and a wash sink.
• Clause 23 The building of any one of clause 19, 21 or 22, wherein a portion of the interior region outside the enclosed interior space includes one or more of a cabinet, a countertop and a cooking facility.
• Clause 24 The building of any one of clauses 17-23, wherein the first wall component comprises:
• a protective layer having a first face, an opposing second face that constitutes the inside surface of the first wall component, with the first face of the protective layer being bonded to the opposing second face of the sheet metal layer;
• Clause 26 The folded building structure of clause 16, further comprising a planar elongate base board having an elongate top edge and an elongate bottom edge, with an elongate hook ledge joined to the top edge of the base board and positioned over the beveled upper edge of the bearing plate of at least one of the toe screw housings of the fourth plurality of toe screw housings.

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• 2022
  • 2022-01-28 WO PCT/US2022/014224 patent/WO2022231675A1/en active Application Filing
  • 2022-01-28 AU AU2022268186A patent/AU2022268186A1/en active Pending
  • 2022-01-28 EP EP22796310.5A patent/EP4330481A1/de not_active Withdrawn

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