Abstract:
Self-contained, modular building systems that create temporary structures consisting of various panels that fold compactly for shipping, but that deploy into complete building segments, such that a large surface area of panels sufficient to provide a structure of superior size as compared with like known modular structures may be efficiently stored and conveniently deployed.

Description:
FIELD OF INVENTION 
     The present invention relates generally to self-contained, modular building systems and methods for their deployment and storage. 
     BACKGROUND OF THE INVENTION 
     The desirability of sturdy, reliable, readily transportable, and easily deployed temporary shelters has been recognized since the dawn of time. Over the millennia, a variety of tent structures have been developed and are used to this day. New flexible, strong materials, such as Fibreglas®, polycarbonate, and other high-strength, lightweight, flexible polymeric materials have enabled new designs, for example “dome” tents, but these do not provide the maximum interior space often required for extended use. Nor do tents provide a sturdy, reliable structure that is durable enough for long-term use and that is capable of withstanding a variety of extreme environmental conditions. 
     While modular structures created from pre-fabricated parts are known, they also are limited in their application. Although such structures may allow for sturdier, more durable, and larger-sized shelter than do tents, they are not lightweight and do not provide the compactability when stored, portability, and ease of deployment required in many circumstances. Even other approaches developed for smaller transportable buildings that unfold in different ways are severely limited in their applicability. For example, one known structure folds in an accordion-like fashion. However, by virtue of its design, in order for it to fit into a standard shipping container it is limited to relatively small structures. Other known systems that employ folding, hinged panels have very complicated hinge mechanisms and require expensive, complicated tracks and leveling devices in order that the structure may be deployed without the hinge mechanisms jamming. In addition, such structures are severely limited in the terrain in which they may be deployed. 
     The ideal modular, non-permanent structure would be capable of long-term use under a variety of environmental and field conditions. It would be relatively lightweight, self-contained, and easily deployable. The ideal structure would be capable of being stored compactly in a rigid container that is optimally suitable for shipping. 
     BRIEF SUMMARY OF THE INVENTION 
     Accordingly, it is the principal object of the present invention to provide modular building systems that overcome the deficiencies of known temporary structures. 
     It is another object of the present invention to provide modular building systems that create a structure that is sturdy, reliable, readily transportable, and easily deployed. 
     It is a further object of the present invention to provide modular building systems that create a structure that is self-contained when stored in a compact container that is suitable for shipping. 
     It is yet another object of the present invention to provide modular building systems that create a structure that allows each pre-deployed segment to be moved through the interior of previously deployed segments of the shelter before its expansion 
     The present invention relates to self-contained, modular building systems capable of providing relatively rigid, stable temporary structures that are sturdy, reliable, readily transportable, and easily deployed. The modules of the present invention each consist of various panels that fold compactly for shipping, but which easily deploy into complete building segments. An important feature of the systems of the present invention is that the size of the structures that they create is limited only by the size of the container used. Furthermore, a structure built using the systems of the present invention can be combined with one or more other like or compatible such structures to form a still larger structure that can also vary not only in its dimensions, but also in its configuration. For example, two rectangular structures could be combined to form one elongated rectangular structure, a T-shaped structure, or an L-shaped structure. Other combinations and possibilities are limited only by the number, design, and dimensions of the modules used and by the imagination of the designer/builder. 
     The systems of the present invention are unique in that they allow a large surface area of panels to be stored efficiently in a container from which they may be conveniently deployed. This results in temporary structures that have the maximum height, width, length, and floor area possible for a structure that is self-contained in one shipping container. 
     Other aspects and advantages of the present invention will be apparent upon consideration of the following detailed description hereof which includes numerous illustrative examples of the practice of the invention, with reference being made to the following figures: 
    
    
     DESCRIPTION OF THE FIGURES 
     FIG. 1 shows a self-contained, modular building of the present invention packaged for shipping. 
     FIG. 2A shows a self-contained, modular building of the present invention in sequential states of deployment. 
     FIG. 2B shows an end elevation of a fully deployed self-contained, modular building of the present invention. 
     FIG. 2C shows a perspective view of a fully deployed self-contained, modular building of the present invention. 
     FIG. 3A shows an embodiment of the side wall-to-floor joint of a self-contained, modular building of the present invention. 
     FIG. 3B shows an embodiment of a gasket suitable for connecting adjoining panels of different modules of a self-contained, modular building of the present invention. 
     FIG. 3C shows a gasket suitable for connecting adjoining roof panels of different modules of a self-contained, modular building of the present invention. 
     FIGS. 4A-C show one means by which a self-contained, modular building unit of the present invention having a unitary floor and two roof panels may be folded for storage. 
     FIGS. 5A-C show another means by which a self-contained, modular building unit of the present invention having a unitary floor and two roof panels may be folded for storage. 
     FIGS. 6A-B show a third means by which a self-contained, modular building unit of the present invention having a unitary floor and two roof panels may be folded for storage. 
     FIGS. 7A-C show one means by which a self-contained, modular building unit of the present invention having a segmented floor may be folded for storage. 
     FIGS. 8A-C show another means by which a self-contained, modular building unit of the present invention having a segmented floor may be folded for storage. 
    
    
     DETAILED DESCRIPTION 
     As shown in the Figures, the present invention relates to a modular building system  10  that folds for storage into a self-contained, shippable unit  20 . Each building module of the present invention consists of a floor  12 , left and right side wall panels  14  and  16 , respectively, and roof  18 . It is understood that the structure is bilaterally symmetrical and that where only one half of the structure is shown in the figures, the mirror half of the structure is formed and functions identically to the half illustrated. 
     In the preferred embodiment, hinge  22  at the floor-to-side-wall joint is located along floor  12  at some distance A from the intersection of floor  12  and side wall  14 . 
     As shown more particularly in FIG. 3A, each wall panel comprises a wall segment  17  and a flange segment  15  extending inwardly at an angle from the wall segment  17  for the distance A. The angle between the wall segment and the flange segment may be substantially equal to or less than 90°. This construction allows roof panel  18  to first be folded down against side wall  14  before side wall  14  is folded down against floor  12  for storage, as shown in FIGS. 4A-4C. In addition, and perhaps more importantly, because the folded panel module is narrower than the deployed module, each pre-deployed panel set may be moved through the interior of previously deployed segments before deployment. 
     In an alternate embodiment shown in FIGS. 7A-C and  8 A-C, the hinge line at the floor to side wall joint is located at the intersection of the floor  12  and side wall  14 . In this embodimnent, the floor is composed of two panels  32  and  34  that are hinged, as shown in FIG. 7, or connectable to each other, as shown in FIG.  8 . 
     The system is designed to be moved from its shipping position to its approximate erection position as a unit. However, the panel connection details of the module may be such that individual panels or all panels optionally can be detached to reduce the size and weight of the panels, if necessary. This removable panel provision also allows for the simplified insertion of “special” component panels, such as optional panels having side wall doors, windows, vents, electrical connections, air conditioning ports, or roof skylights. It also allows for the convenient repair or replacement of damaged panel sections in a module. Other special parts may be employed, such as panels to form the triangular gable ends  28 . 
     FIG. 2A shows four modules,  40 ,  50 ,  60 , and  80  in sequential phases of deployment. Module  80  is deployed by moving it through previously deployed modules  40 - 60 . Floor panel  82  is deployed approximately adjacent to and parallel with floor panel  62  of the previous module. A gasket  36  (see FIG. 3B) is then optionally inserted between floor panels  82  and  62 , such that they are connected. Gasket  36  also provides resistance to groundwater and vermin penetration of the floor. Jack  92  may be used to level floor panel  82  prior to its connection with floor panel  62 . The use of such jacks is particularly desirable where the structure is to be deployed on uneven or debris-strewn terrain, where it is desirable to have space beneath floor  12  for electrical or other equipment, or where there is risk of flooding. In addition, center jacks  92  similarly may be used to increase the rigidity and load capacity of floor  12 . The use of center jacks is particularly desirable where floor  12  is composed of more than one panel, as shown in FIGS. 7 and 8. 
     Left and right panel sets  84  and  86  respectively, of linked side wall and roof panels are then unfolded so that they are relatively perpendicular to floor  82 . Note that in certain embodiments, particularly in embodiments where each side of the roof is one unitary panel, the fully deployed position of the side wall panels may be up to about ten degrees less than the normal line to floor  12 , such as is shown in FIGS. 4-6. 
     That is, the angle between the flange segment  15  and the wall segment  17  of each panel is about 80°. 
     Unlike conventional building systems, the structures of the present invention may also employ guy wires  110 , as shown in FIGS. 2B and C, to increase their stiffness and resistance to wind and snow loads, making such structures a hybrid of tent and conventional rigid wall building technology. Where it is desirable to stabilize the deployed structure by means of guy wires  110 , side panels  14  and  16  may be guyed to the ground before the roof is deployed. 
     As shown in module  50  of FIG. 2A, left roof panel  24  and right roof panel  26  are then unfolded from left and right side wall panels  14  and  16 , respectively, and joined to form structure peak  120 . The connection between left roof panel  24  and right roof panel  26  may be achieved by means of a leak-proof connection means, such as gasket  36 ′ shown in FIG. 3 C. The system optionally includes a folding truss  130  that may be deployed to support the roof. 
     Where roof  18  is formed from more than one panel, the lowest roof panel is deployed first, followed by the upper roof panel(s). These separate roof panels may either fold against each other or be slidable against each other for storage. Where the panels fold against each other, hinges or functionally equivalent joining means are employed. Where the panels are slidable against each other, such slidability is achieved by means of rollers, tracks, bearings, or other functionally equivalent means. The upper panel(s) optionally may overlap the lower panel(s), adding to the water-tightness and structural performance of the joints. 
     The trailing edges of this newly-deployed module would then be biased tightly against the leading edges of the previously-deployed module and joined in position by appropriate connections. The process would then be repeated with the next undeployed module panel set in the shipping package. 
     Structures constructed in accordance with the principles of the present invention may be broken down and refolded and re-stored for shipment in a variety of ways, as determined by their construction. FIGS. 4C-A,  5 C-A, and  6 C-A show three possible methods of folding a module having single right and left roof panels and a unitary floor. FIGS. 7C-A show how a module having a floor composed of right and left hinged segments may be folded for storage. FIGS. 8C-A show how a module having a floor composed of right and left segments that separate may be folded for storage. 
     In accordance with the principles of the present invention, shipping container  20  may form one segment of the usable space in the fully deployed structure. Generally, side wall  20 ′ of the container initially would be removed so that the folded panel sets may be deployed. As shown in FIG. 2C, side wall  20 ′ then would be used as the end wall of the completed structure. 
     In one embodiment, the present invention comprises a new type of mobile building that will pack into an 8×8×20 foot shipping container, and then deploy to form a building with a nominal size of 20×96 feet. It is contemplated that this modular building system could be used for any sized building packaged in any container or shipping system. This embodiment of the invention may be efficiently packaged into the shipping container, pallet, or military container shelter, and deployed to construct a building. 
     Panels used in structures constructed in accordance with the principles of the present invention may be made of any material, including wood, sheet or corrugated metal, or sandwich construction. In one embodiment, sandwich panels consisting of a lightweight foam or honeycomb core and glass fiber-reinforced plastic composite skins may be used. Panel edge details such as hinges and close-outs may be formed into the panel during the initial fabrication, resulting in a single unitized part, or they may be bonded, bolted, riveted, or otherwise joined in a secondary operation. Not all panels need to be of the same construction. For example, where bearing a snow load is not a factor, the roof panels may be made of a lightweight, less-rigid material than are the load-bearing wall panels. Employing guy wires further allows for reductions in weight and load strength of the panels. 
     It will now be apparent to those skilled in the art that other embodiments, improvements, details and uses can be made consistent with the letter and spirit of the foregoing disclosure and within the scope of this patent, which is limited only by the following claims, construed in accordance with the patent law, including the doctrine of equivalents.