WO2022231680A1 - Bâtiments transportables pliables - Google Patents

Bâtiments transportables pliables Download PDF

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Publication number
WO2022231680A1
WO2022231680A1 PCT/US2022/016999 US2022016999W WO2022231680A1 WO 2022231680 A1 WO2022231680 A1 WO 2022231680A1 US 2022016999 W US2022016999 W US 2022016999W WO 2022231680 A1 WO2022231680 A1 WO 2022231680A1
Authority
WO
WIPO (PCT)
Prior art keywords
edge
face
floor
fork tube
plate
Prior art date
Application number
PCT/US2022/016999
Other languages
English (en)
Inventor
Paolo Tiramani
Galiano TIRAMANI
Kyle DENMAN
Original Assignee
Build Ip Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from PCT/US2021/056415 external-priority patent/WO2022154844A1/fr
Priority claimed from PCT/US2021/059440 external-priority patent/WO2022154855A1/fr
Priority claimed from US17/527,520 external-priority patent/US20220220725A1/en
Application filed by Build Ip Llc filed Critical Build Ip Llc
Priority to JP2023566904A priority Critical patent/JP2024516257A/ja
Priority to AU2022264681A priority patent/AU2022264681B2/en
Priority to EP22796315.4A priority patent/EP4330480A1/fr
Priority to CA3216637A priority patent/CA3216637A1/fr
Publication of WO2022231680A1 publication Critical patent/WO2022231680A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315—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
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34384—Assembling details for foldable, separable, collapsible or retractable structures
    • 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
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/005—Modulation co-ordination
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/02—Dwelling houses; Buildings for temporary habitation, e.g. summer houses
    • E04H1/04—Apartment houses arranged in two or more levels

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 are directed to a spacer system for stacked enclosure components, which comprises a first enclosure component having a horizontal first surface, an opposed horizontal second surface and an edge with an edge length, and a planar elongate first seal plate having a first seal plate edge, an opposed second seal plate edge, a seal plate exterior face, an opposed seal plate interior face and a seal plate thickness.
  • the first seal plate edge is provided with a first set of stepped locating ridges extending from the first seal plate edge inwardly into the seal plate thickness toward the second seal plate edge, and the seal plate interior face secured to the edge of the first enclosure component.
  • a spacer plate that includes a planar base having a spacer plate exterior face, an opposed spacer plate interior face, a spacer plate thickness, and a lip extending away from the spacer plate interior face, with the lip having an edge distal from the spacer plate interior face which includes a second set of stepped locating ridges.
  • the spacer plate interior face is positioned against the horizontal first surface of the first enclosure component adjacent the edge of the first enclosure component, with the second set of stepped locating ridges in a mating relationship with the first set of stepped locating ridges.
  • the present inventions are directed to a folded building structure transportable to a desired site at which the building structure is to be erected, which comprises a fixed space portion that includes a planar rectangular first floor portion having first and second longitudinal floor edges, first and second transverse floor edges and a thickness, with the first floor portion comprising across its thickness (i) a first structural layer having a first face and an opposing second face; (ii) a foam panel layer having a first face and an opposing second face, the first face of the foam panel layer being bonded to the opposing second face of the first structural layer; (iii) a second structural layer having a first face and an opposing second face, the first face of the second structural layer being bonded to the opposing second face of the foam panel layer; and (iv) a first edge reinforcement proximate the first longitudinal floor edge, and a second edge reinforcement proximate the second longitudinal floor edge.
  • the first floor portion includes (i) a first fork tube oriented in a transverse direction and spanning the distance from the first longitudinal floor edge to the second longitudinal- floor edge so as to define a first aperture in the first longitudinal floor edge and a second aperture in the second longitudinal floor edge, (ii) a planar elongate longitudinally-oriented first fork tube plate secured to the first edge reinforcement and to the first fork tube; and (iv) a planar elongate longitudinally-oriented second fork tube plate secured to the second edge reinforcement and to the first fork tube.
  • 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 finished structure shown in Figure 1.
  • Figures 4 and 5 are partial cutaway views of a finished 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.
  • Figures 8A is a perspective view of a foldable I-beam for a floor component in accordance with the present inventions, in the beam unfolded position
  • Figure 8B is a side view of a foldable I-beam for a floor component in accordance with the present inventions, in the beam folded position.
  • Figure 9A is a schematic perspective view of a fork tube arrangement for a floor portion in accordance with the present inventions
  • Figure 9B is a schematic cut-away perspective view of a fork tube arrangement, positioned within a floor portion, in accordance with the present inventions
  • Figure 9C is a schematic cut-away perspective view of a floor component in accordance with the present inventions.
  • Figure 10 is a schematic side view of an I-beam end cap in accordance with the present inventions.
  • Figure 11 A is a section view of a compression seal in accordance with the present inventions
  • Figure 1 IB is a side view of a roof bottom plate with a compression seal provided in one of its two seal slots in accordance with the present inventions.
  • Figure 12 is an exploded side view of the junction between a wall vertical interlock and a wall end cap in accordance with the present inventions
  • Figure 13 is an exploded side view of the junction between a roof bottom plate and a wall end cap in accordance with the present inventions.
  • Figures 14 is an exploded side view of the junction between an I-beam interlock A and an I-beam interlock B in accordance with the present inventions.
  • Figure 15 is an exploded side view of the junction between a floor top plate and a wall end cap in accordance with the present inventions.
  • Figure 16A is a section view of a shear seal in accordance with the present inventions
  • Figure 16B is a side view of a wall end interlock with a shear seal provided in its seal slot in accordance with the present inventions.
  • Figure 17 is an exploded side view of the junction between a floor top interlock and a wall end interlock A in accordance with the present inventions.
  • Figure 18 is an exploded side view of the junction between a wall end interlock B and a wall end interlock A in accordance with the present inventions.
  • Figure 19A is a side view of the junction between a perimeter board and an I-beam end cap in accordance with the present inventions
  • Figure 19B is a depiction of the positioning of an I-beam end cap, a floor top plate, a wall end cap and a perimeter board in accordance with the present inventions.
  • Figure 20 is a side view of the junction between a roof skirt board and an I-beam end lock in accordance with the present inventions.
  • Figure 21 A is an exploded perspective view of a finished structure in accordance with the present inventions, depicting suitable locations for the sealing systems of the present inventions on the horizontally positioned enclosure components
  • Figure 21B is an exploded perspective view of a finished structure in accordance with the present inventions, depicting correspondingly suitable locations for the sealing systems of the present inventions on the vertically positioned enclosure components.
  • Figure 22 depicts the layout of a three room structure fabricated in accordance with the present inventions.
  • Figure 23 is a perspective view of a two story structure fabricated in accordance with the present inventions.
  • Figure 24 is a perspective view of an exemplary spacer plate in accordance with the present inventions.
  • Figure 25 is a side view depicting the arrangement of spacer plates in connection with two stacked structures.
  • 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 (wall component 200, floor component 300 and roof component 400) 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. As a result, 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 the metal sheets 206 of first structural layer 210 using a suitable adhesive, preferably a polyurethane-based construction adhesive.
  • Foam panel layer 213 can include exterior edge reinforcement and interior edge reinforcement, as described further below.
  • Second structural layer 215 having a first face that is positioned on the second opposing face 212 of foam panels 214 (the face distal from first structural layer 210), and also having a second opposing face.
  • 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, which has 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 the foam panel material of foam panel layer 213 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 the foam panel material of foam panel layer 213 which 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. E. Enclosure Component Load Transfer
  • 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).
  • wall component 200 floor component 300, and roof component 400 are provided in the sections following.
  • a 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 110.
  • the hinge structures referenced above, 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 such 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 by means of hinge structures 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 referenced 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 such hinge structures.
  • Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material.
  • 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 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.
  • 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 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 structure 150, in addition to protecting the edges of foam panel material of the foam panel layer 213.
  • 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 floor portions 300a and 300b in plan view
  • Figure 4 shows floor portions 300a and 300b 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 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 a fully unfolded position, shown in Figures 2 and 4, where floor portion 300b is horizontally oriented and co-planar with floor portion 300a.
  • suitable hinge structures for joining floor portion 300a to floor portion 300b are described below.
  • Figure 8A shows a beam assembly 325 that can be placed within floor component 300 to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne by floor component 300 to its edges.
  • Beam assembly 325 includes two I-beams 326a and 326b.
  • I-beam 326a is positioned approximately in the middle of floor portion 300a
  • I-beam 326b is positioned approximately in the middle of floor portion 300b
  • each of I-beams 326a and 326b is oriented in the transverse direction.
  • a hinge assembly 329A joins I-beam 326a to I-beam 326b.
  • the hinge assembly 329A permits beam assembly 325 to be folded to a beam folded position shown in Figure 8B and unfolded to a beam unfolded position shown in Figure 8A. Further, the hinge assembly 329A can be locked when beam assembly 325 is in the beam unfolded position, which transforms beam assembly 325 into a rigid structure that will reinforce floor component 300 in the direction perpendicular to its axis of folding.
  • Hinge assembly 329A comprises two identical hinge assembly portions 330A partnered together to form a pivoted junction, as shown in Figures 8 A and 8B.
  • a detailed description of the construction of hinge assembly 329A and its hinge assembly portions 330A is set forth in U.S. Nonprovisional Patent Application No. 17/527,520 entitled “Folding Beam Systems”, filed November 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Nonprovisional Patent Application No.
  • I-beam assembly 325 is located at the mid-point between first transverse floor edge 120 and second transverse floor edge 118, and no hinge assemblies 329A are utilized elsewhere within floor component 300, such as proximate to first transverse floor edge 120 and second transverse floor edge 118. Therefore, to assist in smoothly rotating floor portion 300b, there is provided adjacent first transverse floor edge 120 a first floor end hinge assembly 345A joining floor portions 300a and 300b, and there is provided adjacent second transverse floor edge 118 a second floor end hinge assembly 345 A joining floor portions 300a and 300b.
  • Floor end hinge assembly 345 A comprises two identical floor end hinge portions 350A (not specified in the figures).
  • a description of the construction of floor end hinge assembly 345 A and its floor end hinge portions 350A is set forth in U.S. Nonprovisional Patent Application No. 17/527,520 entitled “Folding Beam Systems”, filed November 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Nonprovisional Patent Application No.
  • Figure 9A depicts two fork tubes, 360a and 360b.
  • These fork tubes 360a, 360b are spaced-apart elongate members and oriented in the transverse direction within floor portion 300a as shown, for example, in Figure 9B.
  • Fork tubes 360a, 360b flank an I-beam 326a between them, which I-beam 326a assists in the transfer of vertical loads to the fourth footing beam 320 that is adjacent second longitudinal floor edge 119, as shown, for example, in Figure 9B, and to the reinforcing board 307 that is positioned in floor portion 300a adjacent interior edge 301a as shown, for example, in Figure 9C.
  • Hinge assembly 329A assists in further transferring those vertical loads to I- beam 326b positioned in floor portion 300b, and then to second footing beam 320 adjacent first longitudinal floor edge 117.
  • I-beams 326a, 326B and hinge assembly 329A are disclosed in U.S. Provisional Patent Application No. 63/188,101, filed May 13, 2021, entitled “Folding Beam Systems” and having the same inventors as the subject application. The contents of that U.S. Provisional Patent Application No.
  • Fork tubes 360a, 360b in the embodiment shown herein have a rectangular cross section and are made for example of steel.
  • the specifics of I-beams 326a, 326B and hinge assembly 329A are also set forth in U.S. Nonprovisional Patent Application No. 17/527,520 entitled “Folding Beam Systems”, filed November 16, 2021 and having the same inventors as the subject application, as mentioned above. The contents of that U.S.
  • Nonprovisional Patent Application No. 17/527,520 entitled “Folding Beam Systems”, filed November 16, 2021 and having the same inventors as the subject application, are likewise incorporated by reference as if fully set forth herein, particularly the description of I-beams 326a, 326B and hinge assembly 329A set forth for example in 3 ⁇ 4 0074-0089 and in Figures 8A-13E thereof
  • Figure 9B depicts the placement of fork tubes 360a, 360b within the structure of floor portion 300a.
  • Each fork tube 360a, 360b rests on, or is defined in part by, sheet metal layer 205, and channels are provided in foam panels 214 (not shown in Figure 9) to accommodate the fork tubes.
  • Fork tubes 360a, and 360b are of sufficient length to span the distance between second longitudinal floor edge 119 and interior edge 301a of floor portion 300a, and thus present rectangular apertures 362 at each of these two edges.
  • cut-outs are provided in the fourth footing beam 320 adjacent second longitudinal floor edge 119, and, as shown in Figure 9B, in the reinforcing board 307 that is positioned in floor portion 300a adjacent interior edge 301a, to permit fork tubes 360a, 360b to pass through footing beam 320 and reinforcing board 307.
  • I-beam end cap 221 (e.g., shown in Figure 10) positioned adjacent second longitudinal floor edge 119, and in I-beam interlock 251 (e.g., shown in Figures 14 and 21A) positioned adjacent interior edge 301a, to permit fork tubes 360a, 360b to pass through that I-beam end cap 221 and I-beam interlock 251.
  • a fork tube plate 361a positioned against fourth footing beam 320
  • a fork tube plate 361b positioned against fourth footing beam 320.
  • Fork tube plate 361a approximately spans the longitudinal distance between I-beam 326a and fork tube 360a, and extends beyond fork tube 360a in the longitudinal direction toward first transverse floor edge 120.
  • fork tube plate 361b approximately spans the longitudinal distance between I-beam 326a and fork tube 360b, and extends beyond fork tube 360b in the longitudinal direction toward second transverse floor edge 118.
  • a fork tube plate 361c (visible in Figure 9A), which is positioned against the reinforcing board 307 within floor portion 300a that is adjacent interior edge 301a
  • a fork tube plate 361d (visible in Figure 9A), which is positioned against the reinforcing board 307 within floor portion 300a that is adjacent interior edge 301a.
  • Fork tube plate 361c approximately spans the longitudinal distance between I-beam 326a and fork tube 360a, and extends beyond fork tube 360a in the longitudinal direction toward first transverse floor edge 120.
  • fork tube plate 36 Id approximately spans the longitudinal distance between I-beam 326a and fork tube 360b, and extends beyond fork tube 360b in the longitudinal direction toward second transverse floor edge 118.
  • Fork tube plates 361a, 361b, 361c and 361d in the embodiment shown herein are made for example of steel.
  • Fork tube plates 361a and 361b can be secured to fourth footing beam 320 with adhesive and/or fasteners such as screws, and fork tube plates 361c and 361d can be secured to the reinforcing board 307 within floor portion 300a which is adjacent interior edge 301a with adhesive and/or fasteners such as screws.
  • fork tube plates 361a and 361c can be secured to fork tube 360a, and fork tube plates 361b and 36 Id can be secured to fork tube 360b, in each case utilizing for example fasteners or welding.
  • 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.
  • 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.
  • Structure 150 can utilize the enclosure component sealing systems described below to limit or prevent the ingress of rain water, noise and outside air into the interior of structure 150.
  • the enclosure component sealing systems for structure 150 utilize the sealing structures described below. Except for I-beam end cap 221, which functions to seal the edges of select enclosure components 155, the enclosure component sealing systems comprise in general terms two enclosure component sealing structures, paired in in pressing contact in different combinations, to seal the junctions between different regions of the enclosure components 155 found in structure 150. These junctions consist of either two interior edges of adjacent enclosure component portions, positioned edge-to-edge when structure 150 is unfolded, or an exterior edge of an enclosure component 155 which abuts an interior surface of another enclosure component 155.
  • an enclosure component sealing structure is positioned on an interior or exterior edge of an enclosure component 155, there can respectively be provided interior edge reinforcement or exterior edge reinforcement between the sealing structure and the respective interior or exterior edge of the foam panel layer 213 in the case where the multi-layered, laminate design depicted in Figure 7 is utilized (such that the enclosure component sealing structure is positioned proximate to the interior or exterior edge, as the case may be, of the foam panel layer 213).
  • the specific enclosure component sealing structures described below are I-beam end cap 221; wall vertical interlock 245; wall end cap 246; I-beam interlock A 250; I-beam interlock B 251; floor top plate 252; roof bottom plate 255; floor top interlock 261; wall end interlock A 262; and wall end interlock B 263.
  • each of the foregoing enclosure component sealing structures utilizes either two or more compression seals 230, or one shear seal 260, which are also described below. Exemplary placements of the enclosure component sealing structures described herein are found in Subsections B. through J. below and also in the Section below entitled “Enclosure Component Sealing Structure Exemplary Placements”.
  • the current inventions include two closure boards, namely perimeter board 310 and roof skirt board 280. These closure boards, which are described below, are utilized in conjunction with I-beam end cap 221 to provide additional sealing, as well as to realize additional benefits.
  • I-beam end cap 221 shown in cross-section in Figure 10, is a rigid elongate member that is fastened to the periphery of select enclosure components 155, preferably the exterior edges of floor component 300 and roof component 400.
  • I-beam end cap 221 constitutes an edge seal that performs a sealing function against water ingress into and environmental exposure of the edge of the enclosure component 155 to which it is secured, and imparts impact resistance to that edge.
  • FIG 10 shows an exemplary installation of I-beam end cap 221 secured to the edge of a schematic representation of floor portion 300a.
  • I-beam end cap 221 has an elongate seal plate 223 with seal plate 223 having an elongate interior face 226 and an opposing elongate planar exterior face 227.
  • I-beam end cap 221 has a length and width the same, or substantially the same, as the length and width of the exterior edge of floor portion 300a, so as to cover the entirety, or substantially the entirety, of the exterior edge of floor portion 300a.
  • an elongate key 222 which is rectangular in cross section (as shown in Figure 10), and has a length the same, or substantially the same, as the length of I-beam end cap 221. Key 222 is received in a corresponding slot formed in the exterior edge reinforcement positioned on the exterior edge of the enclosure component 155 to which I-beam end cap 221 is secured.
  • Figure 9 depicts key 222 of an I-beam end cap 221 received in slot 422 of a shoulder beam 435 of roof portion 400a.
  • Each of the top and bottom edges of I-beam end cap 221 define locating slots 229.
  • locating slots 229 receive the edge portions 207 of metal sheets 206 and 217 (of sheet metal layers 205 and 216 respectively), bent down at a ninety degree (90°) angle, as shown in Figure 9.
  • the exterior face 227 of seal plate 223 of I-beam end cap 221 includes an elongate accessory slot 224, which is rectangular in cross section and has a length the same, or substantially the same, as the length of the exterior face 227 of I-beam end cap 221.
  • the exterior face 227 further includes a plurality of elongate fastener locating grooves 225, each of which has a length the same, or substantially the same, as the length of seal plate 223.
  • I-beam end cap 221 can be secured to an exterior edge of an enclosure component 155, such as the roof portion 400a shown in Figure 9 and the floor portion 300a shown in Figure 10, for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of I-beam end cap 221 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners. Locating grooves 225 assist in accurate positioning of such fasteners.
  • a number of the enclosure component sealing systems described herein and utilized in structure 150 include a compression seal system.
  • An element of that compression seal system is a compression seal 230.
  • Compression seal 230 which is shown in cross-section in Figure 11 A, is an elongate member having in cross-section an elongate base 231 with an elongate arched portion 232 that is flanked by two elongate winglets 233. At the intersection of the arched portion 232 of base 231 and each of the winglets 233, there are provided two opposed elongate seal walls 234, joined to and extending away from base 231 in a diverging relationship at a divergence angle Q, where Q ⁇ 180°, for example Q ⁇ 90° or in the range of 40° ⁇ Q ⁇ 50°. It is most preferred that Q be the same, or nearly so, as the divergence angle e of the slot walls 244 described below.
  • the ends of the seal walls 234 distal from base 231 are further apart than the ends of the seal walls proximate to base 231.
  • each seal wall 234 is joined to an elongate arcuate buttress 235.
  • the end of each arcuate buttress 235, distal from the seal wall 234 to which it is joined, is in turn joined to a respective planar elongate seal surface 236; thus there are two planar seal surfaces 236 in compression seal 230.
  • the planar seal surfaces 236 extend away from the seal walls 234 in a converging relationship at a convergence angle d, where d ⁇ 180°, for example 90°.
  • d convergence angle
  • seal surfaces 236 distal from arcuate buttresses 235 are joined by an elongate seal closure 237.
  • the base 231, seal walls 234, arcuate buttresses 235, seal surfaces 236 and seal closure 237 thereby define a hollow elongate seal chamber 238, as shown in Figure 11A.
  • Seal closure 237 is curved in shape toward seal chamber 238, such as to assume a cupped appearance.
  • Seal 230 is intended to be received in an elongate seal slot 240, shown for example in Figure 1 IB.
  • Slot 240 in general has a dovetail shape, with an elongate planar floor 241 flanked by two elongate lateral grooves 242, and with an elongate planar slot wall 244 abutting and extending from each groove 242 toward an elongate shoulder 243 at the surface of the slot 240.
  • planar slot walls 244 extend away from grooves 242 in a diverging relationship at a divergence angle e, where e ⁇ 180° (for example e ⁇ 90° or in the range of 40° ⁇ e ⁇ 50°), such that the edges of slot walls 244 coincident with shoulders 243 are further apart than the edges of slot walls 244 abutting grooves 242.
  • Compression seal 230 is dimensioned to snugly fit within slot 240, as shown in Figure 1 IB, such that winglets 233 are received in grooves 242 and the arched portion 232 of base 231 is compressed sufficiently to provide a resilient force that urges winglets 233 into grooves 242 and causes seal 230 to be retained in its proper position in slot 240 during fabrication and following fabrication of the enclosure component 155.
  • Compression seal 230 can be fabricated from a resilient material, such as rubber or plastic, for example polyurethane. Particular embodiments of enclosure component sealing structures utilizing the foregoing compression sealing system are described below.
  • Figure 12 depicts in exploded form the junction between a wall vertical interlock 245 and a wall end cap 246.
  • the particular junction is shown for illustrative purposes between wall portion 200s- 1 and 200s-2, with wall vertical interlock 245 positioned on the interior vertical edge of wall portion 200s-2 (interior vertical edge 192-2 shown in Figure 2) and wall end cap 246 positioned on the interior vertical edge of wall portion 200s- 1 (interior vertical edge 192-1 shown in Figure 2).
  • structure 150 wall vertical interlock 245 and wall end cap 246 shown in Figure 12 are vertically-oriented.
  • wall vertical interlock 245 is a rigid elongate member that has an elongate seal plate 223 with an elongate interior face 226 and an opposing elongate planar exterior face 227.
  • the exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • Seal plate 223 has a length and width the same, or substantially the same, as the length and width of the interior edge of wall portion 200s-2, so as to cover the entirety, or substantially the entirety, of that interior edge of wall portion 200s-2.
  • an elongate key 222 which is rectangular in cross section has a length the same, or substantially the same, as the length of seal plate 223. Key 222 is received in a corresponding elongate slot formed in the interior edge reinforcement positioned on the interior vertical edge of wall portion 200s-2, to which wall vertical interlock 245 is secured.
  • Each of the top and bottom edges of wall vertical interlock 245 define elongate locating slots 229 for receiving the edge portions of sheet metal layers 205 and 216, when bent down at a ninety degree (90°) angle.
  • edge of one of the slots 229 abutting the interior face 226 of wall vertical interlock 245 is terminated an inset distance “I” from the opposing edge of that slot, where I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.
  • I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.
  • an elongate interlock slot 228, which is rectangular in cross-section and has a length the same, or substantially the same, as the length of the exterior face 227 of wall vertical interlock 245.
  • Two elongate seal slots 240 are defined on the exterior face 227 of wall vertical interlock 245, one above interlock slot 228 and the other below interlock slot 228, as shown in Figure 12.
  • Each slot 240 has a length the same, or substantially the same, as the length of wall vertical interlock 245.
  • Wall vertical interlock 245 can be secured to the vertical edge of wall portion 200s-2 shown in Figure 12 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall vertical interlock 245 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • Figure 12 additionally depicts a wall end cap 246.
  • Wall end cap 246 shown in Figure 12 is a rigid elongate member that is defined by an elongate seal plate 223 having an elongate interior face 226 and an opposing elongate planar exterior face 227.
  • the exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • Seal plate 223 has a length and width the same, or substantially the same, as the length and width of the exterior edge of wall portion 200s- 1, so as to cover the entirety, or substantially the entirety, of the vertical edge of wall portion 200s- 1 shown in in Figure 12.
  • an elongate key 222 which is rectangular in cross-section and has a length the same, or substantially the same, as the length of seal plate 223.
  • Key 222 of wall end cap 246 is received in a corresponding elongate slot formed in the interior edge reinforcement, positioned on the interior vertical edge of wall portion 200s- 1, to which wall end cap 246 is secured.
  • Each of the top and bottom edges of wall end cap 246 define elongate locating slots 229 for receiving the edge portions of sheet metal layers 205 and 216, when bent down at a ninety degree (90°) angle.
  • Wall end cap 246 can be secured to the vertical edge of wall portion 200s- 1 shown in Figure 12 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end cap 246 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • wall vertical interlock 245 mates with wall end cap 246.
  • an elongate interlock key 247 which is rectangular in cross-section and has a length the same, or substantially the same, as the length of the exterior face 227 of wall end cap 246.
  • Interlock key 247 mates with interlock slot 228 when wall vertical interlock 245 and wall end cap 246 are pressed together.
  • the two edges of wall end cap 246 are provided with elongate coupling ridges 248 which mate with elongate coupling insets
  • Coupling ridges 248 and coupling insets 249 can have the same, or approximately the same, lengths as wall end cap 246 and wall vertical interlock 245 respectively.
  • a compression seal 230 is placed in each of the two seal slots 240 of wall vertical interlock 245, with each seal 230 having the same, or approximately the same, length as the slot 240 in which it is inserted.
  • the two compression seals 230 are deformed in the manner described previously to provide four lines of sealing between wall vertical interlock 245 and wall end cap 246.
  • Figure 14 depicts in exploded form the junction between an I-beam interlock A
  • I-beam interlock A 250 and I-beam interlock B 251 are horizontally oriented.
  • I-beam interlock A 250 is a rigid elongate member that is defined by an elongate seal plate 223 having an elongate interior face 226 and an opposing elongate planar exterior face 227.
  • the exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • Seal plate 223 has a length and width the same, or substantially the same, as the length and width of the interior edge 412c of roof portion 400c shown in Figure 14, so as to cover the entirety, or substantially the entirety, of that interior edge.
  • an elongate key 222 which has a rectangular cross-section and a length the same, or substantially the same, as the length of I-beam interlock A 250. Key 222 is received in a corresponding elongate slot formed in the interior edge reinforcement positioned on the horizontal edge of roof portion 400c, to which I-beam interlock A 250 is secured.
  • Each of the top and bottom edges of I-beam interlock A 250 define elongate locating slots 229 for receiving the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle.
  • edge of one of the slots 229 abutting the interior face 226 of I-beam interlock A 250 is terminated an inset distance “I” from the opposing edge of that slot, where I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.
  • I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.
  • an elongate interlock slot 228, which has a rectangular cross-section and a length the same, or substantially the same, as the length of the exterior face 227 of I-beam interlock A 250.
  • Three elongate seal slots 240 are defined on the exterior face 227 of I-beam interlock A 250, two above interlock slot 228 and one below interlock slot 228, as shown in Figure 14.
  • Each seal slot 240 has a length the same, or substantially the same, as the length of I-beam interlock A 250.
  • I-beam interlock A 250 can be secured to the interior edge 412c of roof portion 400c shown in Figure 14 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of I-beam interlock A 250 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • FIG 14 additionally depicts an I-beam interlock B 251.
  • I-beam interlock B 251 is a rigid elongate member that is defined by an elongate seal plate 223 having an elongate interior face 226 and an opposing elongate planar exterior face 227.
  • the exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • Seal plate 223 has a length and width the same, or substantially the same, as the length and width of the first interior edge 412b of roof portion 400b, so as to cover the entirety, or substantially the entirety, of that interior edge.
  • I-beam interlock B 251 At the mid-point of the interior face 226 of I-beam interlock B 251 shown in in Figure 14 there is provided an elongate key 222, which has a rectangular cross-section and a length the same, or substantially the same, as the length of I-beam interlock B 251. Key 222 of I-beam interlock B 251 is received in a corresponding elongate slot formed in the exterior edge reinforcement positioned on first interior edge 412b of roof portion 400b, to which I-beam interlock B 251 is secured.
  • Each of the top and bottom edges of I-beam interlock B 251 define elongate locating slots 229 for receiving the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle.
  • edge of one of the slots 229 abutting the interior face 226 of wall end cap 246 is terminated an inset distance “I” from the opposing edge of that slot, where I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.
  • I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.
  • I-beam interlock B 251 can be secured to the first interior edge 412b of roof portion 400b for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of I-beam interlock B 251 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • I-beam interlock A 250 mates with I-beam interlock B 251.
  • an elongate interlock key 247 which has a rectangular cross-section and a length the same, or substantially the same, as the length of I-beam interlock B 251.
  • Interlock key 247 mates with interlock slot 228 when I-beam interlock A 250 and I-beam interlock B 251 are pressed together.
  • I-beam interlock B 251 are provided with elongate coupling ridges 248 which mate with elongate coupling insets 249 located at the exterior edges of I-beam interlock A 250.
  • Coupling ridges 248 and coupling insets 249 can have the same, or approximately the same, lengths as I-beam interlock A 250 and I-beam interlock B 251 respectively.
  • a compression seal 230 is placed in each of the three seal slots 240 of I-beam interlock A 250, with each seal 230 having the same, or approximately the same, length as the slot 240 in which it is inserted.
  • the three compression seals 230 are deformed in the manner described previously to provide six lines of sealing between I-beam interlock A 250 and I-beam interlock B 251.
  • Figure 15 depicts in exploded form the junction between a floor top plate 252 and a wall end cap 246, each shown in cross-section. The particular junction is shown for illustrative purposes between wall component 200R and floor portion 300a, with floor top plate 252 positioned along the upper surface of floor portion 300a adjacent second longitudinal floor edge 119, and with wall end cap 246 positioned on the bottom edge of wall component 200R.
  • wall 200R shown in Figure 15 is vertically oriented and floor portion 300a is horizontally oriented.
  • floor top plate 252 in Figure 15 is a rigid elongate member that has an elongate seal plate 223 with an elongate interior face 226 and an opposing elongate planar exterior face 227.
  • the exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • Seal plate 223 has a length the same, or substantially the same, as the length of second longitudinal floor edge 119, so as to cover the top edge of floor portion 300a proximate to second longitudinal floor edge 119.
  • Seal plate 223 of floor top plate 252 has a width the same, or substantially the same, as the width of wall component 200R.
  • the floor top plate 252 preferably has a thickness “J” sufficient to accommodate the thickness of any protective layer 218 and/or flooring used to surface floor portion 300a, such as stone, wood or carpeting.
  • stepped locating ridges 254 As shown in Figure 15, at the exterior edge of the interior face 226 of floor top plate 252, proximate to second longitudinal floor edge 119, there is provided a series of elongate stepped locating ridges 254. These stepped locating ridges, which have a length the same, or substantially the same, as the length of floor top plate 252, mesh with the corresponding stepped locating ridges 253 shown on I-beam end cap 221 depicted in Figure 10 and with dashed lines in Figure 15.
  • an elongate interlock slot 228, which has a rectangular cross-section and a length the same, or substantially the same, as the length of floor top plate 252.
  • Two elongate seal slots 240 are defined on the exterior face 227 of floor top plate 252, one on each side of interlock slot 228, as shown in Figure 15.
  • Each slot 240 has a length the same, or substantially the same, as the length of floor top plate 252.
  • Floor top plate 252 can be secured to the top edge of floor portion 300a proximate to second longitudinal floor edge 119 shown in Figure 15 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of floor top plate 252 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • Figure 15 additionally depicts a wall end cap 246 positioned along the bottom edge of wall component 200R.
  • the design of wall end cap 246 was previously described in connection with Figure 12.
  • the seal plate 223 of wall end cap 246 shown in Figure 15 has a length and width the same, or substantially the same, as the length and width of the bottom edge of wall component 200R, so as to cover the entirety, or substantially the entirety, of the bottom edge of wall component 200R shown in in Figure 15.
  • Wall end cap 246 can be secured to the bottom edge of wall component 200R shown in Figure 15 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end cap 246 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • floor top plate 252 mates with wall end cap 246.
  • the interlock key 247 of wall end cap 246 is provided with a length the same, or substantially the same, as the length of the exterior face 227 of floor top plate 252. That interlock key 247 mates with the interlock slot 228 of floor top plate 252 when floor top plate 252 and wall end cap 246 are pressed together, with the elongate coupling ridges 248 of wall end cap 246 mating with the elongate coupling insets 249 of floor top plate 252.
  • Coupling ridges 248 and coupling insets 249 can have the same, or approximately the same, lengths as wall end cap 246 and floor top plate 252 respectively.
  • a compression seal 230 is placed in each of the two seal slots 240 of floor top plate 252, with each seal 230 having the same, or approximately the same, length as the seal slot 240 in which it is inserted.
  • the two compression seals 230 are deformed in the manner described previously to provide four lines of sealing between wall end cap 246 and floor top plate 252.
  • Figure 13 depicts in exploded form the junction between a roof bottom plate 255 and a wall end cap 246, each shown in cross-section.
  • the particular junction shown for illustrative purposes is between wall component 200R and roof portion 400a, with roof bottom plate 255 positioned along the lower face of roof portion 400a adjacent second longitudinal roof edge 416, and wall end cap 246 positioned on the top edge of wall component 200R.
  • wall component 200R in Figure 13 is vertically oriented and roof portion 400a is horizontally oriented.
  • roof bottom plate 255 shown in Figure 13 is substantially the same as floor top plate 252 shown in Figure 15, except that roof bottom plate 255 is thinner because it need not accommodate the thickness of any flooring; for example, roof bottom plate 255 can have a thickness “I”, equal to the thickness of an abutting protective layer 218, such as MgO board.
  • Roof bottom plate 255 in Figure 13 is a rigid elongate member that has an elongate seal plate 223 with an elongate planar interior face 226 and an opposing elongate planar exterior face 227.
  • the exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • Seal plate 223 of roof bottom plate 255 has a length the same, or substantially the same, as the length of second longitudinal roof edge 416, so as to cover the bottom edge of roof portion 400a proximate to second longitudinal roof edge 416.
  • Seal plate 223 of roof bottom plate 255 has a width the same, or substantially the same, as the width of wall component 200R.
  • stepped locating ridges 254 As shown in Figure 13, at the exterior edge of the interior face 226 of roof bottom plate 255, proximate to second longitudinal roof edge 416, there is provided a series of elongate stepped locating ridges 254. These stepped locating ridges, which have a length the same, or substantially the same, as the length of roof bottom plate 255, mesh with the corresponding stepped locating ridges 253 of wall end cap 221 depicted in Figure 10 and with dashed lines in Figure 13, and positioned at the exterior edge of roof portion 400a.
  • Roof bottom plate 255 can be secured to the bottom face of roof portion 400a shown in Figure 13 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of roof bottom plate 255 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • Figure 13 additionally depicts a wall end cap 246 positioned along the top edge of wall component 200R.
  • the design of wall end cap 246 was previously described in connection with Figure 12.
  • the seal plate 223 of wall end cap 246 shown in Figure 13 has a length and width the same, or substantially the same, as the length and width of the top edge of wall component 200R, so as to cover the entirety, or substantially the entirety, of the top edge of wall component 200R.
  • Wall end cap 246 can be fastened to that top edge for example by adhesive applied to its interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end cap 246 and driven through its exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • roof bottom plate 255 mates with wall end cap 246.
  • the interlock key 247 of wall end cap 246 is provided with a length the same, or substantially the same, as the length of roof bottom plate 255. That interlock key 247 mates with the interlock slot 228 of roof bottom plate 255 when roof bottom plate 255 and wall end cap 246 are pressed together, with the elongate coupling ridges 248 of wall end cap 246 mating with elongate coupling insets 249 of roof bottom plate 255.
  • Coupling ridges 248 and coupling insets 249 can be the same, or approximately the same, as the lengths of wall end cap 246 and roof bottom plate 255 respectively.
  • a compression seal 230 is placed in each of the two seal slots 240 of roof bottom plate 255, with each seal 230 having the same, or approximately the same, length as the slot 240 in which it is inserted.
  • the two compression seals 230 are deformed in the manner described previously to provide four lines of sealing between roof bottom plate 255 and wall end cap 246.
  • a number of the enclosure component sealing systems described herein and utilized in structure 150 include a shear seal system.
  • An element of that shear seal system is a shear seal 260.
  • Shear seal 260 which is shown in cross-section in Figure 16A, is an elongate member having a planar elongate base 231 flanked by two elongate winglets 233. At the intersection of base 231 and each of the winglets 233, there is provided two opposed elongate seal walls 234 (individually referred to as seal walls 234A, 234B), joined to and extending away from base 231 in a diverging relationship at a divergence angle l where l ⁇ 180°, for example l ⁇ 90° or in the range of 40° ⁇ l ⁇ 50°.
  • seal wall 234B At the end of seal wall 234B distal from base 231, seal wall 234B is joined to an elongate seal closure 237, a planar surface oriented at an upward angle a (relative to the planar orientation of base 231) away from seal wall 234B in a direction toward an elongate seal support 239, described below, with a ⁇ 90°.
  • a planar cantilevered seal surface 257 is joined to the edge of seal closure 237 that is distal from seal wall 234B, as shown in Figure 16A.
  • seal wall 234A At the end of seal wall 234A distal from base 231, seal wall 234A is joined to the elongate seal support 239.
  • seal support 239 Proximate to seal wall 234A, seal support 239 comprises an elongate planar region oriented parallel to base 231. Distal from seal wall 234A, seal support 239 comprises an elongate arcuate buttress region. The edge of the arcuate buttress region of seal support 239, which is distal from seal wall 234A, joins cantilevered seal surface 257 proximate to the junction of cantilevered seal surface 257 and seal closure 237 to define a hollow seal chamber 238. Planar cantilevered seal surface 257 is oriented at an upward angle b away from the junction of arcuate buttress 235 and seal closure 237 and terminates at a free end 258, with b ⁇ 90°, for example b > a.
  • Shear seal 260 is intended to be received in an elongate seal slot 240, shown for example in Figure 16B, which has the same geometry as the seal slots 40 utilized to receive compression seals 230. Shear seal 260 is dimensioned to snugly fit within slot 240, such that winglets 233 of seal 260 are received in grooves 242 of slot 240.
  • An exemplary placement of a shear seal 260 is depicted in Figure 16B, which shows a shear seal 260 placed within the slot 240 of a wall end interlock A 262, described further below.
  • both seal wall 234A and seal wall 234B terminate below the level of exterior face 227 of wall end interlock A 262, with seal wall 234A (underlying planar cantilevered seal surface 257) terminating below the level at which seal wall 234B terminates.
  • Shear seal 260 is preferably utilized where two enclosure components 155 are laterally moved during unfolding, one over the other.
  • the two enclosure components 155 are provided with paired enclosure component sealing structures, with one enclosure component sealing structure mounted on one of the enclosure components 155 (such as on an exterior edge), and the other enclosure component sealing structure mounted on the other of the enclosure component structures 155 (such as on an interior face).
  • Each of the paired enclosure component sealing structures has a shear seal 260, with the two shear seals 260 being oppositely oriented; that is to say, the cantilevered seal surface 257 of each is oriented away from the cantilevered seal surface 257 of the other, and each is oriented in the direction of relative movement.
  • each shear seal 260 is urged into a generally coplanar relationship, with the planar exterior face 227 of the opposing enclosure component seal structure pressing against them, to create an elongate area of sealing.
  • Shear seal 260 can be fabricated from a resilient material, such as rubber or plastic, for example polyurethane. Particular embodiments of enclosure component sealing structures utilizing the foregoing compression sealing system are described below.
  • Figure 17 depicts in exploded form the junction between a floor top interlock 261 and a wall end interlock A 262, each shown in cross-section. The particular junction is shown for illustrative purposes between wall portion 200s-2 and floor portion 300b, with floor top interlock 261 positioned along the upper face of floor portion 300b adjacent first transverse floor edge 120, and with wall end interlock A 262 positioned on the bottom edge of wall portion 200s-2.
  • wall portion 200s-2 in Figure 17 is vertically oriented and floor portion 300b is horizontally oriented.
  • floor top interlock 261 shown in Figure 17 is a rigid elongate member that has an elongate seal plate 223 with an interior face 226 and an opposing planar exterior face 227.
  • the exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • Seal plate 223 has a length the same, or substantially the same, as the dimension of floor portion 300b coinciding with first transverse floor edge 120, so as to cover the top edge of floor portion 300b proximate to first transverse floor edge 120.
  • Seal plate 223 of floor top interlock 261 has a width the same, or substantially the same, as the width of wall portion 200s-2.
  • the floor top interlock 261 preferably has a thickness “J” at its interior edge, as shown in Figure 17, sufficient to accommodate the thickness of any protective layer 218 and/or flooring used to surface floor portion 300b, such as stone, wood or carpeting.
  • an elongate seal slot 240 is defined on the exterior face 227 of floor top interlock 261, proximate to the exterior edge of floor portion 300b (such exterior edge coincides with first transverse floor edge 120). Seal slot 240 has a length the same, or substantially the same, as the length of floor top interlock 261.
  • Floor top interlock 261 can be secured to the top edge of floor portion 300b at first transverse floor edge 120 shown in Figure 17 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of floor top interlock 261 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • Wall end interlock A 262, also shown in Figure 17, is a rigid elongate member that has an elongate seal plate 223 with an interior face 226 and an opposing exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • the seal plate 223 of wall end interlock A 262 has a length and width the same, or substantially the same, as the length and width of the bottom edge of wall portion 200s-2, so as to cover the entirety, or substantially the entirety, of the bottom edge of wall portion 200s-2, as shown in in Figure 17.
  • an elongate key 222 which has a rectangular cross section and a length the same, or substantially the same, as the length of wall end interlock A 262. Key 222 is received in a corresponding elongate slot formed in the exterior edge reinforcement positioned on the bottom edge of the wall portion 200s-2 to which wall end interlock A 262 is secured.
  • an elongate seal slot 240 is defined on the exterior face 227 of wall end interlock A 262, toward the interior edge of wall end interlock A 262 (distal from first transverse floor edge 120).
  • This seal slot 240 has a length the same, or substantially the same, as the length of wall end interlock A 262.
  • each of the interior and exterior edges of wall end interlock A 262 define locating slots 229.
  • locating slots 229 receive the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle.
  • Wall end interlock A 262 can be fastened to the bottom edge of wall portion 200s-2 for example by adhesive applied to its interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end interlock A 262 and driven through its exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • floor top interlock 261 mates with wall end interlock A 262.
  • a shear seal 260 is placed in the seal slot 240 of floor top interlock 261, and a shear seal 260 is placed in the seal slot 240 of wall end interlock A 262.
  • the shear seals 260 placed in the seals slots 240 of floor top interlock 261 and wall end interlock A 262 each has the same, or approximately the same, length as the slot 240 in which it is inserted.
  • Mating of floor top interlock 261 with wall end interlock A 262 occurs by the bottom edge of wall portion 200s-2 moving over the top surface of floor portion 300b, from a folded position to an unfolded position.
  • such mating will correspond to a movement of wall portion 200s-2 from the right-hand side of the figure toward the left, with wall end interlock A 262 sliding over floor top interlock 261 until the fully unfolded position is reached.
  • the shear seal 260 in floor top interlock 261, and particularly its seal surface 257 will be in pressing contact with the exterior face 227 of wall end interlock A 262; and the shear seal 260 in wall end interlock A 262, and particularly its seal surface 257, will be in pressing contact with the exterior face 227 of floor top interlock 261.
  • the shear seal 260 placed in seal slot 240 of floor top interlock 261 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 is directed toward the exterior edge of floor top interlock 261 (toward first transverse floor edge 120), and the shear seal 260 placed in the seal slot 240 of wall end interlock A 262 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 is directed toward the interior edge of wall end interlock A 262 (away from first transverse floor edge 120).
  • planar exterior face 227 of floor top interlock 261 not be parallel to the interior face 226 of floor top interlock 261, or to the top face of wall portion 300b, but rather be inclined downward, in the direction moving away from first transverse floor edge 120 at an angle g, as shown in Figure 17.
  • planar exterior face 227 of wall end interlock A 262 be inclined upward, in the direction moving toward first transverse floor edge 120, at the same angle g, as shown in Figure 17.
  • Step-down 268 is an abrupt reduction in the thickness of wall end interlock A 262, in the direction moving from the inside edge of wall end interlock A 262 toward the outside edge of wall end interlock A 262, which outside edge in the case of the junction depicted in Figure 17 is proximate first transverse floor edge 120 when wall portion 200s-2 is in the fully unfolded position.
  • Step-down 268 is located between the slot 240 and the outside edge of wall end interlock A 262.
  • a corresponding step-up 269 on the exterior face 227 of floor top interlock 261.
  • Step-up 269 is an abrupt increase in the thickness of floor top interlock 261, in the direction moving from the inside edge of floor top interlock 261 toward the outside edge of floor top interlock 261, which outside edge in the case of the junction depicted in Figure 17 is proximate first transverse floor edge 120 when floor portion 300b is in the fully unfolded position.
  • Step-up 269 is located between the slot 240 and the inside edge of floor top interlock 261 (distal from first transverse floor edge 120).
  • Step-down 268 and step-up 269 are appropriately located to act as a “stop” and insure correct alignment of wall end interlock A 262 with floor top interlock 261 as wall end interlock A 262 slides over floor top interlock 261.
  • Figure 18 depicts in exploded form the junction between a wall end interlock B 263 and a wall end interlock A 262, each shown in cross-section. The particular junction is shown for illustrative purposes between wall portion 200s-2 and wall component 200P, with wall end interlock B 263 positioned on the interior edge of wall component 200P proximate first transverse edge 108 and wall end interlock A 262 positioned on the vertical edge of wall portion 200s-2 proximate first longitudinal edge 106.
  • wall portion 200s-2 depicted in Figure 18 is vertically oriented and wall component 200P is vertically oriented.
  • wall end interlock B 263 in Figure 18 is an elongate member that has an elongate seal plate 223 with an elongate interior face 226 and an opposing elongate planar exterior face 227.
  • the exterior face 227 preferably is hard and smooth to provide a good sealing surface.
  • Seal plate 223 has a length the same, or substantially the same, as the height of wall component 200P when unfolded, so as to cover the interior edge of wall component 200P proximate to first transverse edge 108.
  • Seal plate 223 of wall end interlock B 263 has a width the same, or substantially the same, as the width of wall portion 200s-2.
  • wall end interlock B 263 is substantially the same as floor top interlock 261 depicted in Figure 17, except wall end interlock B 263 is thinner because it need not accommodate any flooring; for example, wall end interlock B 263 can have a thickness “I” (not shown in Figure 18) at its interior edge equal to the thickness of an abutting protective layer 218, such as MgO board.
  • an elongate seal slot 240 is defined on the exterior face 227 of wall end interlock B 263, proximate the interior edge of wall component 200P positioned adjacent to first longitudinal edge 106. Seal slot 240 has a length the same, or substantially the same, as the length of wall end interlock B 263.
  • Wall end interlock B 263 can be secured to the interior edge of wall component 200P as shown in Figure 18 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end interlock B 263 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • Figure 18 additionally shows a wall end interlock A 262 positioned along the depicted vertical edge of wall portion 200s-2.
  • the design of wall end interlock A 262 was previously disclosed in connection with Figure 17.
  • the seal plate 223 of the wall end interlock A 262 shown in Figure 18 has a length and width the same, or substantially the same, as the length and width of the depicted vertical edge of wall portion 200s-2, so as to cover the entirety, or substantially the entirety, of that vertical edge of wall portion 200s-2, as shown in in Figure 18.
  • the elongate rectangular key 222 of wall end interlock A 262 shown in Figure 18 has a length the same, or substantially the same, as the length of that wall end interlock A 262.
  • the seal slot 240 of wall end interlock A 262 shown in Figure 18 has a length the same, or substantially the same, as the length of that wall end interlock A 262.
  • the enclosure component 155 in this case wall portion 200s-2, utilizes the enclosure component laminate design shown in Figure 7, the locating slots 229 of wall end interlock A 262 shown in Figure 18 receive the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle.
  • Wall end interlock A 262 can be secured to the vertical edge of wall portion 200s-2 shown in Figure 18 for example by adhesive applied to its interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end interlock A 262 and driven through its exterior face 227, or by utilizing a combination of adhesive and fasteners.
  • wall end interlock A 262 mates with a wall end interlock B 263.
  • a shear seal 260 is placed in the seal slot 240 of wall end interlock A 262, and a shear seal 260 is placed in the seal slot 240 of wall end interlock B 263.
  • Each of the shear seals 260 placed in the seals slots 240 of wall end interlock A 262 and a wall end interlock B 263 has the same, or approximately the same, length as the slot 240 in which it is inserted.
  • Mating of wall end interlock A 262 and a wall end interlock B 263 occurs by the vertical edge of wall portion 200s-2 depicted in Figure 18 swinging toward and across the interior surface of wall component 200P, as wall portion 200s-2 moves from a folded position to an unfolded position.
  • such mating will correspond to a movement of wall portion 200s-2 from the top of the figure toward the bottom, with wall end interlock A 262 sliding across wall end interlock B 263 until the fully unfolded position is reached.
  • the shear seal 260 in wall end interlock A 262, and particularly its seal surface 257 will be in pressing contact with the exterior face 227 of wall end interlock B 263; and the shear seal 260 in wall end interlock B 263, and particularly its seal surface 257, will be in pressing contact with the exterior face 227 of wall end interlock A 262.
  • the shear seal 260 placed in seal slot 240 of floor top interlock B 263 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 is directed toward the exterior edge of wall end interlock B 263 (toward first transverse edge 108), and the shear seal 260 placed in the seal slot 240 of wall end interlock A 262 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 is directed toward the interior edge of wall end interlock A 262 (away from first transverse edge 108).
  • planar exterior face 227 of wall end interlock B 263 not be parallel to the interior face 226 of wall end interlock B or to the interior face of wall component 200P, but rather be inclined at an angle g, as shown in Figure 17, so that seal plate 223 of wall end interlock B 263 becomes progressively thinner moving away from first transverse edge 108.
  • planar exterior face 227 of wall end interlock A 262 be inclined at the same angle g, as shown in Figure 17, so that seal plate 223 of wall end interlock A 262 becomes progressively thicker moving away from first transverse edge 108.
  • Step-down 268 is an abrupt reduction in the thickness of wall end interlock A 262, in the direction moving from the inside edge of wall end interlock A 262 toward the outside edge of wall end interlock A 262, which outside edge in the case of the junction depicted in Figure 18 is proximate first transverse edge 108 when wall portion 200s-2 is in the fully unfolded position.
  • Step-down 268 is positioned between the slot 240 and the outside edge of wall end interlock A 262 (proximate transverse edge 108), as depicted in Figure 18.
  • a corresponding step-up 269 is provided on the exterior face 227 of wall end interlock B 263.
  • Step-up 269 is an abrupt increase in thickness of wall end interlock B 263, in the direction moving from the inside edge of wall end interlock B 263 toward the outside edge of wall end interlock B 263, which outside edge in the case of the junction depicted in Figure 18 is proximate first transverse edge 108.
  • Step-up 269 is positioned between the slot 240 and the inside edge of wall end interlock B 263 (distal from first transverse edge 108).
  • Step-down 268 and step-up 269 are appropriately located to act as a “stop” and insure correct alignment of wall end interlock A 262 with wall end interlock B 263 as wall end interlock A 262 slides across wall end interlock B 263.
  • Perimeter Board (310).
  • the exterior edges of floor component 300, or portions thereof, are optionally provided with a perimeter board 310.
  • FIG. 19A depicts in cross section an exemplary positioning of perimeter board 310.
  • perimeter board 310 is designed to be positioned against an I-beam end cap 221, in this instance the I-beam end cap 221 located on an exterior edge of floor portion 300a.
  • Perimeter board 310 includes an elongate seal plate 223 with an interior face 226 and an opposing exterior face 227. Perimeter board 310 has such length as is desired, such as to span the entirety of the exterior edge of floor portion 300a. As shown in Figure 19A, the width of perimeter board 310 can be sufficient to capture the thickness of the floor component 300a, or floor portion thereof against which it is positioned, plus a portion of the abutting wall component 200 or wall component portion.
  • the interior face 226 of perimeter board 310 includes an elongate locating key 264, which is rectangular in cross section and dimensioned to be received in accessory slot 224 of I-beam end cap 221. Locating key 264 can be the same length as the perimeter board 310, or can comprise space apart discrete segments.
  • the interior face 226 of perimeter board 310 in Figure 19A also includes a plurality of elongate clearance slots 266, rectangular in cross section in the embodiment shown, and having a length the same as, or substantially the same as, the length of perimeter board 310.
  • Clearance slots 266 are preferably located so as to be positioned over locating grooves 225 of I-beam end cap 221 when locating key 264 is received in accessory slot 224. When so located, clearance slots 266 provide space for fastener heads driven into locating grooves 225 of I-beam end cap 221 so that perimeter board 310 can be snugly positioned against I-beam end cap 221.
  • the exterior face 227 of perimeter board 310 depicted in Figure 19A includes two elongate fastener slots 265, each of which has a dovetail shape in cross section in the embodiment shown, and a length the same as, or substantially the same as, the length of perimeter board 310.
  • a locating groove 225 is provided in each fastener slot 265, so as to facilitate the accurate positioning of nails or other fasteners utilized to secure perimeter board 310 to abutting components.
  • Figure 19B depicts in cross section the positioning of I-beam end cap 221, floor top plate 252, wall end cap 246 and perimeter board 310 relative to each other at a junction between wall component 200R and floor portion 300a.
  • perimeter board 310 masks this junction from external view to achieve a more attractive appearance, as well as providing an additional barrier against the ingress of soil, dust, rain and the like.
  • a resilient strip 267 such as those shown in Figure 19B, can be snapped into each of the fastener slots 265 to cover any nail or fastener heads exposed in those slots.
  • roof Skirt Board The exterior edges of roof component 400, or portions thereof, are optionally provided with a roof skirt board 280.
  • FIG. 20 depicts in cross section an exemplary positioning of roof skirt board 280.
  • roof skirt board 280 is designed to be positioned against an I-beam end cap 221, in this instance the I-beam end cap 221 located on an exterior edge of roof portion 400a.
  • Roof skirt board 280 includes an elongate seal plate 223 with an interior face 226 and an opposing exterior face 227. Roof skirt board 280 has such length as is desired, such as to span the entirety of the exterior edge of roof portion 400a. As shown in Figure 20, the width of roof skirt board 280 can be sufficient to capture the thickness of the roof component 400, or portion thereof against which it is positioned, plus a portion of the abutting wall component 200 or wall portion.
  • the interior face 226 of roof skirt board 280 includes an elongate cinch key 278, which is preferably serpentine in cross section and dimensioned to be received in accessory slot 224 of I-beam end cap 221.
  • Cinch key 278 can be the same length as the perimeter board 310, or can comprise space apart discrete segments.
  • the exterior face 227 of roof skirt board 280 includes an elongate fastener slot 265 positioned over cinch key 278.
  • Fastener slot 265 has a dovetail shape in cross section in the embodiment shown, and a length the same as, or substantially the same as, the length of roof skirt board 280.
  • An elongate locating groove 225 is provided in the fastener slot 265 of roof skirt board 280, and provides a visual indication of where to place fasteners during construction.
  • Roof skirt board 280 facilitates the securing of roofing material, such as thermoplastic polyolefin membrane, to wall components 200.
  • roofing material such as thermoplastic polyolefin membrane
  • roofing material is optionally used to cover the top of roof component 400.
  • the roofing material extending beyond roof component 400 is then folded down to extend between exterior face 227 of I-beam end cap 221 of roof portion 400a shown in Figure 20 and interior face 226 of roof skirt board 280.
  • nails or other fasteners are driven at spaced intervals along locating groove 225, to press roof skirt board 280 against the roofing material and secure the roofing material in place between roof skirt board 280 and I-beam end cap 221.
  • An elongate resilient strip 267, such as the one shown in Figure 20, can be snapped into fastener slot 265 to cover any nail or fastener heads exposed in this slot.
  • the enclosure component sealing structures described herein can be fabricated from a number of materials, such as wood, aluminum, plastics and the like. It is preferred to fabricate the enclosure component sealing structures from foamed polyvinyl chloride (PVC), particularly Celuka foamed PVC. This material provides a strong, impact and crack-resistant lightweight material with a hard attractive exterior, which, in addition to contributing a sealing function, additionally contributes to the structural rigidity of the enclosure components 155.
  • PVC polyvinyl chloride
  • Celuka foamed PVC This material provides a strong, impact and crack-resistant lightweight material with a hard attractive exterior, which, in addition to contributing a sealing function, additionally contributes to the structural rigidity of the enclosure components 155.
  • FIG. 21A and 21B of structure 150 depicted in Figure 1 provide exemplary placements of the enclosure component sealing structures described herein. For illustrative purposes to better understand some of these exemplary placements, certain of the enclosure component sealing structures shown in Figures 21A and 21B are shown slightly separated from the enclosure component 155 to which they are fastened.
  • I-beam end caps 221 can be utilized to seal the horizontal exterior edges of floor portion 300a (three placements), floor portion 300b (three placements), roof portion 300a (three placements), roof portion 300b (two placements) and roof portion 300c (three placements). Further, as shown in Figure 2 IB and in detail in Figure 12, the hinged junction between wall portion 200s- 1 and 200s-2 can be sealed by positioning a wall end cap 246 on the vertical edge of wall portion 200s- 1 and a wall vertical interlock 245 on the vertical edge of wall portion 200s-2.
  • the hinged vertical junction between wall portion 200s-3 and 200s-4 can be sealed as shown in Figure 2 IB by positioning a wall end cap 246 on the hinged vertical edge of wall portion 200s-3 and a wall vertical interlock 245 on the hinged vertical edge of wall portion 200s-4.
  • the horizontal junction between wall component 200R and roof portion 400a can be sealed by positioning a roof bottom plate 255 on the bottom face of roof portion 400a overlying wall component 200R and by positioning a wall end cap 246 on the horizontal edge of wall component 200R, which supports roof portion 400a.
  • a like seal arrangement can be used to seal the horizontal junctions between roof portions 400a, 400b and 400c, and wall portions 200s- 1 through 200s-4 (unfolded roof portion 400b will rest on unfolded wall portion 200s-2 and also on a section of wall portion 200s- 1, as can be appreciated from Figure 3), as well as to seal the horizontal junction between roof portion 400c and wall component 200P.
  • the two vertical exterior edges of wall component 200R can each be sealed by positioning on each of them a wall end cap 246.
  • the horizontal junction between wall component 200R and floor portion 300a can be sealed by positioning a wall end cap 246 on the horizontal edge of wall component 200R resting on floor portion 300a and by positioning on the top face of floor portion 300a underlying wall component 200R a floor top plate 252.
  • a like seal arrangement can be used to seal the horizontal junctions between floor portion 300b and wall component 200P, and between floor portion 300a and wall portions 200s- 1 and 200s-3, up to the point where wall portion 200s- 1 meets wall portion 200s-2, and up to the point where wall portion 200s-3 meets wall portion 200s-4.
  • the two vertical exterior edges of wall component 200P can be sealed by positioning on each of them a wall end cap 246.
  • the hinged horizontal junction between roof portion 400b and roof portion 400c can be sealed by positioning an I-beam interlock A 250 on interior edge 412c of roof portion 400c, and an I- beam interlock B 251 on first interior edge 412b of roof portion 400b.
  • the hinged horizontal junction between roof portion 400a and roof portion 400b shown in Figure 21 A can be sealed by positioning an I-beam interlock A 250 on second interior edge 412b of roof portion 400b, and an I-beam interlock B 251 on interior edge 412a of roof portion 400a.
  • the hinged horizontal junction between floor portion 300a and floor portion 300b can be sealed by positioning an I-beam interlock A 250 on the interior edge 301b of floor portion 300b and an I-beam interlock B 251 on the interior edge 301a of floor portion 300a.
  • the horizontal junction between wall portion 200s-2 and floor portions 300a and 300b can be sealed by positioning a wall end interlock A 262 on the bottom edge of wall portion 200s-2 and a floor top interlock 261 on the regions of the upper face of floor portions 300a and 300b underlying wall portion 200s-2 when wall portion 200s-2 is in its fully unfolded position.
  • the horizontal junction between wall portion 200s-4 and floor portions 300a and 300b when wall portion 200s-4 in its fully unfolded position can be sealed similarly.
  • the vertical junction between wall portion 200s-2 and wall component 200P can be sealed by positioning a wall end interlock A 262 on the vertical edge of wall portion 200s-2 that is adjacent to wall component 200P when both wall portion 200s-2 and wall component 200P are in their fully unfolded positons, and by positioning a wall end interlock B 263 on the region of the interior face of wall component 200P that is adjacent wall portion 200s-2 when both wall portion 200s-2 and wall component 200P are in their fully unfolded positions.
  • the vertical junction between wall portion 200s-4 and wall component 200P can be sealed in like manner.
  • 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.
  • enclosure components 155 For ease of transport and maximum design flexibility, it is preferred that there be a specific dimensional relationship among enclosure components 155.
  • 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, including perimeter boards 310, 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 (which is stacked upon roof portions 400a and 400b when roof portions 400b, 400c are fully folded) can be dimensioned to be larger than either of roof portion 400a and roof portion 400b in the transverse direction for example, by ten to fifteen percent, or by at least the aggregate thickness of roof components 400a and 400b.
  • This transverse direction dimensional increase is to reduce the chances of binding during the unfolding of roof portions 400b, 400c.
  • 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 corner 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.
  • roof portion 400c can be dimensioned larger than either of roof portions 400a and 400b in the transverse direction by at least the aggregate thickness of roof components 400a and 400b, less the length of the first or second wheel caster.
  • 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.
  • the shipping module 100 shown edge-on in Figure 3 includes a fixed space portion 102 defined by roof component 400a, floor component 300a, wall component 200R, wall portion 200s- 1 and wall portion 200s-3.
  • 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).
  • 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.
  • the fixed space portion 102 be in a relatively finished state prior to positioning (folding) together of all other wall, roof and floor portions as described above.
  • 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, and fixed space portion 102 is fitted during manufacture with all mechanical and other functionality that structure 150 will require, such as kitchens, bathrooms, closets and other interior partitions, storage areas, corridors, etc.
  • 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. Patent No. 11,007,921, issued May 18, 2021; the contents of which 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.
  • the movement of shipping module 100 is facilitated by the presence of fork tubes 360a, 360b in floor portion 300a.
  • a shipping module can be moved from factory to a transport means using an appropriately- sized forklift, with the forks of the forklift being inserted into fork tubes 360a, 360b.
  • straps pending from a reach stacker or a ship-to-shore crane, typically used to move intermodal containers can be passed by ground personnel through fork tubes 360a, 360b and then appropriately secured, to permit movement of the shipping module 100.
  • Addition of perimeter board 310 can be deferred until after shipping module 100 is delivered to its desired location.
  • perimeter board 310 can be provided with cut-outs so as to permit straps or forks to have access to fork tubes 360a, 360b, which cut-outs optionally can be covered and/or filled once access to fork tubes 360a, 360b is no longer needed.
  • 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.
  • the contents of that 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, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at 3 ⁇ 4 00126-00128 and in connection with Figures 11 A and 1 IB thereof.
  • 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. The contents of that U.S. Nonprovisional Patent Application No.
  • Perimeter board 312 and roof skirt board 280 provide structures for securing wall, floor and roof components in their deployed positions.
  • certain appurtenances can be fitted to wall components 200 to facilitate fastening them to floor component 300, as well as to improve the interior appearance and speed fabrication. Further details regarding these appurtenances are described in U.S. Nonprovisional Patent Application No. 17/587,051, entitled “Wall Component Appurtenances,” filed on January 28, 2022 and having the same inventors as this disclosure. The contents of that U.S. Nonprovisional Patent Application No.
  • 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.
  • Any number of structures 150 can be positioned together at the desired site, to yield a multitude of different structural configurations.
  • Interior staircases for such multi story structures can be provided during manufacture in fixed space portion 102, together with insertion of an appropriate access aperture in roof component 400, or can be added after erection.
  • a pitched roof and other architectural additions can be delivered separately from shipping module 100 or fabricated on-site, and positioned onto roof component 400 of structure 150.
  • two or more structures 150 can be erected so that a wall component 200 of one structure is placed adjacent a wall component 200 of the other structure.
  • the builder can then cut apertures in those juxtaposed regions to connect the two structures, either in the factory or on-site, in accordance with the marketer’s or purchaser’s choices.
  • Figure 22 depicts the floor plan of three structures 150, namely 150a, 150b and 150c, arranged side-by-side to yield one housing unit with three rooms.
  • the perimeter boards 310 of the adjoining structures 150 can abut each other, thereby providing a space between the adjoining structures 150 through which utility lines can be passed.
  • Structures 150 can also be stacked, one on top of the other, to create multi-story structures.
  • Figure 23 depicts a structure 150e positioned on top of a structure 150d to yield a two story structure.
  • a garage aperture 203 in addition to door aperture 202 on the first level, as well as a door aperture 202 (not visible) on the second level, which is accessed via exterior stairway 201.
  • spacer plates 404 can be used to separate the floor component 300 of the structure 150e from the roof component 400 of the structure 150d.
  • Figure 24 shows an embodiment of a spacer plate 404, which comprises a planar base 402 having an interior face 407, an opposed exterior face 401 (not visible in Figure 24), and a thickness.
  • the edge 421 of lip 403 distal from interior face 407 is provided with a set of stepped locating ridges 253.
  • the geometry of these ridges 253 is such as to be able to mesh with the corresponding stepped locating ridges 253 shown of I-beam end cap 221.
  • spacer plates 404 can be provided on the bottom surface of the floor component 300 of the upper structure 150 (structure 150e in Figure 23), positioned along the first and second longitudinal floor edges 117 and 119, and along the first and second transverse floor edges 120 and 118. Spacer plates 404 can also be provided on the top surface of the roof component 400 of the lower structure 150 (structure 150d in Figure 23), positioned along the first and second longitudinal roof edges 406 and 416, and along the first transverse and second transverse roof edges 408 and 410.
  • the spacer plates 404 associated with the upper structure 150 can be positioned to overlie the spacer plates 404 associated with the lower structure 150.
  • the spacer plates 404 associated with the upper structure 150 support the weight and loads of the upper structure 150, and transfer that weight and loads to lower structure 150 through the spacer plates 404 associated with lower structure 150.
  • the locating ridges 253 on spacer plates 404 engage the corresponding locating ridges 253 on the I-beam end caps 221 of floor component 300 (shown for floor portion 300a) and roof component 400 (shown for roof portion 400a).
  • spacer plate 404 can be made elongate, or can be provided with a length the same, or substantially the same, as the length of the roof or floor edges at which they are positioned, as preferred. Where the length of spacer plate 404 is less than the length of the roof or floor edges at which they are positioned, a plurality of spacer plates can be provided in segments along those edges, again in accordance with preference. Such spacer plates 404 provide an air barrier between the levels of the multi-story structure. Spacer plates 404 can be made for example from acrylonitrile butadiene styrene plastic or extruded polyvinyl chloride plastic.
  • means can be utilized to secure stacked structures 150 each to the other, such as by use of steel reinforcing plates fastened at spaced-apart locations to join an overlying floor component 300 to an underlying roof component 400.
  • a spacer system for stacked enclosure components comprising:
  • first seal plate having a first seal plate edge, an opposed second seal plate edge, a seal plate exterior face, an opposed seal plate interior face and a seal plate thickness, the first seal plate edge provided with a first set of stepped locating ridges extending from the first seal plate edge inwardly into the seal plate thickness toward the second seal plate edge, and the seal plate interior face secured to the edge of the first enclosure component;
  • a spacer plate including a planar base having a spacer plate exterior face, an opposed spacer plate interior face, a spacer plate thickness, and a lip extending away from the spacer plate interior face, the lip having an edge distal from the spacer plate interior face which includes a second set of stepped locating ridges;
  • a planar elongate first seal plate having a first seal plate edge, an opposed second seal plate edge, a seal plate exterior face, an opposed seal plate interior face and a seal plate thickness, the first seal plate edge provided with a first set of stepped locating ridges extending from the first seal plate edge inwardly into the seal plate thickness toward the second seal plate edge, and the seal plate interior face of the first seal plate secured to the edge of the floor component;
  • a first spacer plate comprising a planar base having a first spacer plate exterior face, an opposed first spacer plate interior face, a thickness, and a lip extending away from the first spacer plate interior face, the lip having an edge distal from the first spacer plate interior face which includes a second set of stepped locating ridges;
  • a roof component having a bottom surface, an opposed top surface and an edge with a roof edge length
  • a planar elongate second seal plate having a first seal plate edge, an opposed second seal plate edge, a seal plate exterior face, an opposed seal plate interior face and a seal plate thickness, the first seal plate edge of the second seal plate provided with a third set of stepped locating ridges extending from the first seal plate edge of the second seal plate inwardly into the seal plate thickness of the second seal plate toward the second seal plate edge thereof, and the seal plate interior face of the second seal plate secured to the edge of the roof component;
  • a second spacer plate comprising a planar base having a second spacer plate exterior face, an opposed second spacer plate interior face, a thickness, and a lip extending away from the second spacer plate interior face, the lip having an edge distal from the second spacer plate interior face which includes a fourth set of stepped locating ridges;
  • the first enclosure component is a planar laminate that includes (i) a planar foam panel layer having a first face and an opposed second face, (ii) a planar first structural layer having an interior face bonded to the first face of the foam panel layer and an exterior face, and (iii) a planar second structural layer bonded to the second face of the foam panel layer.
  • Clause 10 The spacer system of either of clause 8 or clause 9, wherein the exterior face of the first structural layer is coincident with the first surface of the first enclosure component.
  • Clause 11 The spacer system of any one of clauses 8, 9 or 10, wherein the second structural layer is a metal sheet layer.
  • Clause 14 The stacked building structures as in clause 2, wherein the first spacer plate is one of a first plurality of spacer plates positioned against the bottom surface of the floor component adjacent the edge of the floor component.
  • Clause 15 The stacked building structures as in any one of clause 2, 12 or 14, wherein the second spacer plate is one of a second plurality of spacer plates positioned against the top surface of the roof component adjacent the edge of the roof component.
  • Clause 16 The stacked building structures of any one of clauses 2 and 12-15, further comprising a fifth set of stepped locating ridges extending from the second seal plate edge of the first seal plate inwardly into the seal plate thickness toward the first seal plate edge of the first seal plate.
  • Clause 17 The stacked building structures any one of clauses 2 and 12-16, further comprising a sixth set of stepped locating ridges extending from the second seal plate edge of the second seal plate inwardly into the seal plate thickness toward the first seal plate edge of the second seal plate.
  • Clause 18 The stacked building structures any one of clauses 2 and 12-17, wherein each of the first seal plate and the second seal plate is polyvinyl chloride.
  • each of the first spacer plate and the second spacer plate is one of acrylonitrile butadiene styrene or polyvinyl chloride.
  • the floor component is a planar laminate that includes (i) a planar foam panel layer having a first face and an opposed second face, (ii) a planar first structural layer having an interior face bonded to the first face of the foam panel layer and an exterior face, and (iii) a planar second structural layer having a first face, bonded to the second face of the foam panel layer, and an opposed second face.
  • Clause 21 The stacked building structures of clause 20, wherein the first structural layer of the floor component is a metal sheet layer.
  • Clause 22 The stacked building structures of either of clause 20 or 21, wherein the exterior face of the first structural layer of the floor component is coincident with the bottom surface of the floor component.
  • Clause 23 The stacked building structures of any one of clause 20, 21 or 22, wherein the second structural layer of the floor component is a metal sheet layer.
  • the roof component is a planar laminate that includes (i) a planar foam panel layer having a first face and an opposed second face, (ii) a planar first structural layer having an interior face bonded to the first face of the foam panel layer and an exterior face, and (iii) a planar second structural layer having a first face, bonded to the second face of the foam panel layer, and an opposed second face.
  • Clause 26 The stacked building structures of clause 25, wherein the first structural layer of the roof component is a metal sheet layer.
  • Clause 27 The stacked building structures of either of clause 25 or 26, wherein the exterior face of the first structural layer of the roof component is coincident with the top surface of the roof component.
  • Clause 28 The stacked building structures of any one of clause 25, 26 or 27, wherein the second structural layer of the roof component is a metal sheet layer.
  • Clause 29 The stacked building structures of any one of clause 25, 26, 27 or 28, wherein the roof component further comprises a protective layer having a first face and an opposed second face, with the first face of the protective layer bonded to the opposed second face of the second structural layer.
  • a folded building structure transportable to a desired site at which the building structure is to be erected comprising:
  • a fixed space portion including a planar rectangular first floor portion having first and second longitudinal floor edges, first and second transverse floor edges and a thickness, the first floor portion comprising across the thickness
  • a first structural layer having a first face and an opposing second face
  • a foam panel layer having a first face and an opposing second face, the first face of the foam panel layer being bonded to the opposing second face of the first structural layer
  • a second structural layer having a first face and an opposing second face, the first face of the second structural layer being bonded to the opposing second face of the foam panel layer
  • the first floor portion having between the first structural layer and the second structural layer (i) a first fork tube oriented in a transverse direction and spanning the distance from the first longitudinal floor edge to the second longitudinal floor edge so as to define a first aperture in the first longitudinal floor edge and a second aperture in the second longitudinal floor edge, (ii) a planar elongate longitudinally-oriented first fork tube plate secured to the first edge reinforcement and to the first fork tube; and (iv) a planar elongate longitudinally- oriented second fork tube plate secured to the second edge reinforcement and to the first fork tube.
  • Clause 33 The folded building structure of clause 32, wherein the first floor portion additionally has between the first structural layer and the second structural layer (ii) a second fork tube oriented in a transverse direction, spaced apart from the first fork tube and spanning the distance from the first longitudinal floor edge to the second longitudinal floor edge so as to define a third aperture in the first longitudinal floor edge and a fourth aperture in the second longitudinal floor edge, (ii) a planar elongate longitudinally-oriented third fork tube plate secured to the first edge reinforcement and to the second fork tube; and (iv) a planar elongate longitudinally-oriented fourth fork tube plate secured to the second edge reinforcement and to the first fork tube.
  • Clause 34 The folded building structure of clause 33, wherein the first fork tube plate extends beyond the first fork tube along the first edge reinforcement in a direction away from the second fork tube, and the third fork tube plate extends beyond the second fork tube along the first edge reinforcement in an opposite direction away from the first fork tube.
  • Clause 35 The folded building structure of clause 33, wherein the second fork tube plate extends beyond the first fork tube along the second edge reinforcement in a direction away from the second fork tube, and the fourth fork tube plate extends beyond the second fork tube along the second edge reinforcement in an opposite direction away from the first fork tube.
  • Clause 36 The folded building structure of any one of clause 32, 33, 34 or 35, wherein the first structural layer of the floor portion is a metal sheet layer.
  • Clause 37 The folded building structure of any one of clause 33, 34, 35 or 36, wherein the first and second fork tubes are rectangular in cross section.
  • Clause 38 The folded building structure of any one of clause 33, 34, 35, 36 or 37, wherein the first and second fork tubes are in contact with the first structural layer.
  • a planar rectangular second floor portion having third and fourth longitudinal floor edges, third and fourth transverse floor edges and a thickness, the second floor portion having a laminate construction comprising across the thickness (i) a first structural layer having a first face and an opposing second face; (ii) a foam panel layer having a first face and an opposing second face, the first face of the foam panel layer being bonded to the opposing second face of the first structural layer; and (iii) a second structural layer having a first face and an opposing second face, the first face of the second structural layer being bonded to the opposing second face of the foam panel layer; and
  • a folded building structure transportable to a desired site at which the building structure is to be erected comprising:
  • a fixed space portion including a planar rectangular first floor portion having first and second longitudinal floor edges, first and second transverse floor edges and a thickness, the first floor portion having a laminate construction comprising across the thickness
  • a first structural layer having a first face and an opposing second face
  • a foam panel layer having a first face and an opposing second face, the first face of the foam panel layer being bonded to the opposing second face of the first structural layer
  • a second structural layer having a first face and an opposing second face, the first face of the second structural layer being bonded to the opposing second face of the foam panel layer
  • the first floor portion having between the first structural layer and the second structural layer (i) a first fork tube oriented in the transverse direction and spaced-apart to a first side of the first beam, the first fork tube spanning the distance from the first longitudinal edge to the second longitudinal edge so as to define a first aperture in the first longitudinal floor edge and a second aperture in the second longitudinal floor edge, (ii) a planar elongate longitudinally- oriented first fork tube plate positioned against and secured to the first edge reinforcement and to the first fork tube, and having a longitudinal length spanning the distance between the first fork tube and the first beam; and (iv) a planar elongate longitudinally-oriented second fork tube plate positioned against and secured to the second edge reinforcement and to the first fork tube, and having a longitudinal length spanning the distance between the first fork tube and the first beam.
  • first floor portion additionally has between the first structural layer and the second structural layer (ii) a second fork tube oriented in a transverse direction, and spaced-apart to a second side of the first beam opposite the first side, the second fork tube spanning the distance from the first longitudinal edge to the second longitudinal edge so as to define a third aperture in the first longitudinal floor edge and a fourth aperture in the second longitudinal floor edge, (ii) a planar elongate longitudinally-oriented third fork tube plate secured to the first edge reinforcement and to the second fork tube, and having a longitudinal length spanning the distance between the second fork tube and the first beam; and (iv) a planar elongate longitudinally-oriented fourth fork tube plate secured to the second edge reinforcement and to the first fork tube, and having a longitudinal length spanning the distance between the second fork tube and the first beam.
  • Clause 42 The folded building structure of clause 41, wherein the first fork tube plate extends beyond the first fork tube along the first edge reinforcement in a direction away from the first beam, and the third fork tube plate extends beyond the second fork tube along the first edge reinforcement in an opposite direction away from the first beam.
  • Clause 43 The folded building structure of either of clause 41 or clause 42, wherein the second fork tube plate extends beyond the first fork tube along the second edge reinforcement in a direction away from the first beam, and the fourth fork tube plate extends beyond the second fork tube along the second edge reinforcement in an opposite direction away from the first beam.
  • Clause 44 The folded building structure of any one of clause 40, 41, 42 or 43, wherein the first structural layer of the floor portion is a metal sheet layer.
  • Clause 45 The folded building structure of any one of clause 41, 42, 43 or 44, wherein the first and second fork tubes are rectangular in cross section.
  • Clause 46 The folded building structure of clause 45, wherein the first and second fork tubes are in contact with the first structural layer.
  • a planar rectangular second floor portion having third and fourth longitudinal floor edges, third and fourth transverse floor edges and a thickness, the second floor portion having a laminate construction comprising across the thickness (i) a first structural layer having a first face and an opposing second face; (ii) a foam panel layer having a first face and an opposing second face, the first face of the foam panel layer being bonded to the opposing second face of the first structural layer; and (iii) a second structural layer having a first face and an opposing second face, the first face of the second structural layer being bonded to the opposing second face of the foam panel layer;
  • Clause 48 The folded building structure of any one of clauses 33-35, 37-38 and 41-
  • each of the third and fourth fork tube plates is a metal.
  • Clause 50 The folded building structure of any one of clauses 32-49, wherein the first fork tube is a metal.
  • Clause 51 The folded building structure of any one of clauses 32-50, wherein each of the first and second fork tube plates is a metal.
  • Clause 52 The folded building structure of any one of clause 48, 49, 50 and 51, wherein the metal is steel.
  • Clause 53 The folded building structure of any one of clauses 32-52, wherein each of the first and second edge reinforcements is laminated strand lumber board.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Pallets (AREA)
  • Stackable Containers (AREA)
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Abstract

L'invention concerne un système d'espacement pour des structures de construction empilées qui est en prise d'accouplement avec une plaque d'étanchéité disposée sur un bord d'un composant d'enceinte, et un agencement de tube de fourche pour faciliter le mouvement d'un module d'expédition.
PCT/US2022/016999 2021-04-29 2022-02-18 Bâtiments transportables pliables WO2022231680A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
JP2023566904A JP2024516257A (ja) 2021-04-29 2022-02-18 折り畳み可能で運搬可能な建築物
AU2022264681A AU2022264681B2 (en) 2021-04-29 2022-02-18 Foldable transportable buildings
EP22796315.4A EP4330480A1 (fr) 2021-04-29 2022-02-18 Bâtiments transportables pliables
CA3216637A CA3216637A1 (fr) 2021-04-29 2022-02-18 Batiments transportables pliables

Applications Claiming Priority (14)

Application Number Priority Date Filing Date Title
US202163181447P 2021-04-29 2021-04-29
US63/181,447 2021-04-29
US202163188101P 2021-05-13 2021-05-13
US63/188,101 2021-05-13
US202163192349P 2021-05-24 2021-05-24
US63/192,349 2021-05-24
US202163196400P 2021-06-03 2021-06-03
US63/196,400 2021-06-03
USPCT/US2021/056415 2021-10-25
PCT/US2021/056415 WO2022154844A1 (fr) 2021-01-12 2021-10-25 Systèmes d'étanchéité de composants d'enceinte
USPCT/US2021/059440 2021-11-16
PCT/US2021/059440 WO2022154855A1 (fr) 2021-01-12 2021-11-16 Systèmes de poutres pliantes
US17/527,520 2021-11-16
US17/527,520 US20220220725A1 (en) 2021-01-12 2021-11-16 Folding Beam Systems

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WO2022231680A1 true WO2022231680A1 (fr) 2022-11-03

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JP (1) JP2024516257A (fr)
AU (1) AU2022264681B2 (fr)
CA (1) CA3216637A1 (fr)
WO (1) WO2022231680A1 (fr)

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AU2022264681A1 (en) 2023-11-16

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