Wall Component Appurtenances

A toe screw housing, for securing abutting enclosure components together, having a bearing plate with an interior face, an exterior face and a beveled upper edge; a toe screw well joined to and extending away from the interior face and including a fastener shelf; a toe screw support joined to the interior face, and additionally joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a second angle relative to the interior face of the bearing plate.

BACKGROUND OF THE INVENTION

Field of the Invention

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.

Description of the Related Art

In the field of residential housing, the traditional technique for building homes is referred to as “stick-built” construction, where a builder constructs housing at the intended location using in substantial part raw materials such as wooden boards, plywood panels, and steel columns. The materials are assembled piece by piece over a previously prepared portion of ground, for example, a poured concrete slab or a poured concrete or cinder block foundation.

There have been a variety of efforts to depart from the conventional construction techniques used to create dwellings, as well as commercial spaces and like, in an effort to reduce costs. In this regard, significant advancements in the construction of dwellings and commercial space have been made by the current inventors, as exemplified by their patent documents, including U.S. Pat. Nos. 8,474,194, 8,733,029, 10,688,906, 10,829,029, 10,926,689 and 11,220,816. In one aspect, these patents pertain to fabricating wall, floor and roof components in a factory that are folded together into a compact shipping module, and which are then transported to the intended location and unfolded to yield a fully formed structure.

SUMMARY OF THE INVENTION

The present inventions describe advancements in the design of appurtenances for building structures, particularly for the wall components of such structures.

In a first aspect, the present inventions are directed to a toe screw housing for securing abutting enclosure components together. The toe screw housing comprises a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face. There is provided a toe screw well, joined to and extending away from the interior face of the bearing plate, which includes a fastener shelf, and there is provided a toe screw support that is joined to the interior face of the toe screw housing, and which is also joined to and extending away from the fastener shelf. The toe screw support distal from the fastener shelf includes a planar support surface oriented perpendicular to the interior face. A fastener bore passes through the fastener shelf, the toe screw support and the support surface, and is inclined at a non-perpendicular second angle relative to the interior face of the bearing plate.

In a second aspect, the present inventions are directed to a baseboard for masking a toe screw bearing plate that has a beveled upper edge. The baseboard comprises a planar elongate member having an elongate interior face, an elongate top edge and an elongate bottom edge. An elongate hook ledge is joined to the top edge of the base board to form a wedge-shaped angled slot that is oriented to be open in the direction of the bottom edge, with the wedge-shaped angled slot configured to be positioned over the beveled upper edge of the bearing plate. There is provided an elongate linear first step positioned on the interior face below the angled slot to form an elongate first recess on the interior face configured to receive the toe screw bearing plate, and there is provided an elongate second step positioned on the interior face below the elongate first step to form an elongate second recess on the interior face.

These and other aspects of the present inventions are described in the drawings annexed hereto, and in the description of the preferred embodiments and claims set forth below.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An embodiment of the foldable, transportable structure150in which the inventions disclosed herein can be implemented is depicted inFIGS. 1 through 5. When fully unfolded, as exemplified byFIG. 1, structure150has a rectangular shape made of three types of generally planar and rectangular enclosure components155, the three types of enclosure components155consisting of a wall component200, a floor component300, and a roof component400. As shown inFIGS. 1 and 2, the perimeter of structure150is defined by first longitudinal edge106, first transverse edge108, second longitudinal edge116and second transverse edge110. For convenience, a direction parallel to first longitudinal edge106and second longitudinal edge116may be referred to as the “longitudinal” direction, a direction parallel to first transverse edge108and second transverse edge110may be referred to as the “transverse” direction; and a direction parallel to the vertical direction inFIG. 1may be referred to as the “vertical” direction. Structure150as shown has one floor component300, one roof component400and four wall components200; although it should be understood that the present inventions are applicable to structures having other configurations as well.

Enclosure components155(wall component200, floor component300and roof component400) can be fabricated and dimensioned as described herein and positioned together to form a shipping module100, shown end-on inFIG. 3. The enclosure components155are dimensioned so that the shipping module100is within U.S. federal highway dimensional restrictions. As a result, shipping module100can be transported over a limited access highway more easily, and with appropriate trailering equipment, transported without the need for oversize permits. Thus, the basic components of structure150can be manufactured in a factory, positioned together to form the shipping module100, and the modules100can be transported to the desired site for the structure, where they can be readily assembled, as described herein.

Enclosure Component (155): General Description

The enclosure components155of the present invention include a number of shared design features that are described below.

A. Laminate Structure Design

Enclosure components155can be fabricated using a multi-layered, laminate design. A particular laminate design that can be used to fabricate enclosure components155comprises a first structural layer210, a foam panel layer213, a second structural layer215and a protective layer218, as shown inFIG. 7and described further below.

In particular, first structural layer210is provided in the embodiment of enclosure component155that is depicted inFIG. 7. First structural layer210in the embodiment shown comprises a sheet metal layer205, which can be for example galvanized steel or aluminum. Sheet metal layer205is made from a plurality of generally planar rectangular metal sheets206positioned adjacent to each other to generally cover the full area of the intended enclosure component155.

Referring again toFIG. 7, there is next provided in the depicted embodiment of enclosure component155a foam panel layer213, comprising a plurality of generally planar rectangular foam panels214collectively presenting a first face211and a second opposing face212. Foam panels214are made for example of expanded polystyrene (EPS) foam. A number of these foam panels214are positioned adjacent to each other and superposed first face-down on first structural layer210to generally cover the full area of the intended enclosure component155. The foam panels214of foam panel layer213preferably are fastened to first structural layer210using a suitable adhesive, preferably a polyurethane based construction adhesive.

In the embodiment of the enclosure component155depicted inFIG. 7, there is next provided a second structural layer215, having a first face that is positioned on the second opposing face212of foam panels214(the face distal from first structural layer210), and also having a second opposing face. Second structural layer215in the embodiment shown comprises a sheet metal layer216, which can be for example galvanized steel or aluminum. Sheet metal layer216is made from a plurality of generally planar rectangular metal sheets217positioned adjacent to each other and superposed first face-down on the second opposing face of foam panel layer213to generally cover the full area of the intended enclosure component155. The metal sheets217of second structural layer215preferably are fastened to foam panel layer213using a suitable adhesive, preferably a polyurethane based construction adhesive.

In the embodiment of the enclosure component155depicted inFIG. 7, there is optionally next provided a protective layer218, having a first face that is positioned on the second opposing face of second structural layer215(the face distal from foam panel layer213), and also having a second opposing face. Optional protective layer218in the embodiment shown comprises a plurality of rectangular structural building panels219principally comprising an inorganic composition of relatively high strength, such as magnesium oxide (MgO). The structural building panels219are positioned adjacent to each other and superposed first face-down on the second opposing face of second structural layer215to generally cover the full area of the intended enclosure component155. The building panels219of protective layer218preferably are fastened to second structural layer215using a suitable adhesive, preferably a polyurethane based construction adhesive. Protective layer218can be used if desired to impart a degree of fire resistance to the enclosure component155, as well as to provide a pleasing texture and/or feel.

Other embodiments of multi-layered, laminate designs that can be used to fabricate the enclosure components155of the present invention, are described in U.S. Nonprovisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures,” filed on Feb. 10, 2020 and now issued as U.S. Pat. No. 11,118,344. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures” and filed on Feb. 10, 2020 are incorporated by reference as if fully set forth herein, particularly including the multi-layered, laminate designs described for example at0034-57 and depicted in FIGS. 4A-4D thereof.

B. Enclosure Component Exterior Edge Reinforcement

The exterior edges of each enclosure component155(i.e., the edges that define the perimeter of enclosure component155) can be provided with exterior edge reinforcement, as desired. Exterior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the exterior edges of enclosure components155. 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 component155with fasteners, such as screw or nail fasteners, and/or adhesive.

C. Enclosure Component Partitioning

Enclosure components155in certain instances are partitioned into enclosure component portions to facilitate forming a compact shipping module100. In those instances where an enclosure component155is partitioned into enclosure component portions, any exterior edge reinforcement on the exterior edges defining the perimeter of the enclosure component is segmented as necessary between or among the portions.

The enclosure component portions can be joined by hinge structures or mechanisms to permit the enclosure component portions to be “folded” and thereby contribute to forming a compact shipping module100.

D. Enclosure Component Interior Edge Reinforcement

An enclosure component155partitioned into enclosure component portions will have interior edges. There will be two adjacent interior edges for each adjacent pair of enclosure component portions. Such interior edges can be provided with interior edge reinforcement. Similar to exterior edge reinforcement, such interior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the interior edges of enclosure components155. 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 component155with fasteners, such as screw or nail fasteners, and/or adhesive.

E. Enclosure Component Load Transfer

In the case of enclosure components155, 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. For enclosure components155that are horizontally oriented when in use (floor component300and roof component400), such loads include the weight of equipment, furniture and people borne by their surfaces, as well as vertical seismic loads. For enclosure components that are vertically oriented when in use (wall component200), such loads include those arising from meteorological conditions (hurricanes, tornadoes, etc.) and human action (vehicle and other object impacts).

For this purpose, multi-layered, laminate designs as shown inFIG. 7will function to transfer the loads described above. To add additional load transfer capability, structural members, such as beams and/or joists, can be utilized within the perimeter of the enclosure components155, as is deemed appropriate to the specific design of structure150and the particular enclosure component155, to assist in the transfer of loads to the exterior edges. Particular embodiments of such structural members, which also incorporate hinge structures, are described in U.S. Nonprovisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as this disclosure. The contents of that U.S. Nonprovisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as this disclosure, is incorporated by reference as if fully set forth herein, particularly the description of the hinged load transfer components set forth for example in0074-0089 and 0104-0126 and in FIGS. 8A-13E and 15A-24A thereof, as well as the description of the associated end hinge assemblies set forth for example in0090-0093 and 0127-0132 and in FIGS. 14A-14B, 24B and 25A-25D thereof.

F. Enclosure Component Sealing Systems

Structure150comprises a number of wall, floor and roof components with abutting or exposed exterior edges, as well as a number of partitioned wall, floor and roof components with interior edges. In this regard, sealing structures can be utilized, with the objective to limit or prevent the ingress of rain water, noise and outside air across these exterior and interior edges into the interior of structure150.

Particular sealing structures for accomplishing the foregoing objective are described in PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as the present application. The contents of that PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as this disclosure, are incorporated by reference as if fully set forth herein, particularly including the sealing systems described for example at0080-0167 and depicted in FIGS. 9-20 thereof, and also including the exemplary placements for such sealing systems described in0168-0174 and depicted in FIGS. 8A-8B thereof.

Further design details of wall component200, floor component300, and roof component400are provided in the sections following.

Wall Component (200)

Typically, structure150will utilize four wall components200, with each wall component200corresponding to an entire wall of structure150.

A. General Description

Wall component200has a generally rectangular perimeter. As shown inFIG. 1, wall components200have plural apertures, specifically a door aperture202, which has a door frame and door assembly, and plural window apertures204, each of which has a window frame and a window assembly. The height and length of wall components200can vary in accordance with design preference, subject as desired to the dimensional restrictions applicable to transport, described above. In this disclosure, structure150is fashioned with all sides of equal length; accordingly, its first and second longitudinal edges106and116, and its first and second transverse edges108and110, 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 components200are longer than the other two opposing wall components200.

As indicated above, wall components200of the present inventions can utilize a multi-layered, laminate design. In the embodiment depicted inFIGS. 1 through 6, wall component200utilizes the multi-layered, laminate design shown inFIG. 7employing these particular elements: sheet metal layer205of first structural layer210is 24 gauge galvanized steel approximately 0.022-0.028 inch thick, the foam panels214of foam panel layer213are EPS foam approximately 5.68 inches thick, the sheet metal layer216of second structural layer215is 24 gauge galvanized steel approximately 0.022-0.028 inch thick, and the building panels219of protective layer218are MgO board approximately 0.25 inch (6 mm) thick.

The perimeter of each wall component200is generally provided with exterior edge reinforcement. As exemplified by wall component200shown inFIG. 6, the exterior edge reinforcement for wall component200is a floor plate220along the bottom horizontal edge, a ceiling plate240along the top horizontal edge and two end pieces270respectively fastened at each vertical edge of wall component200. In the case of a wall component200, exterior edge reinforcement provides regions for fastening like regions of abutting wall components200, roof component400and floor component300, in addition to protecting the exterior edges of foam panel material. In the embodiment shown inFIGS. 1 through 6, the exterior edge reinforcement for wall component200provided by floor plate220, ceiling plate240, and end pieces270is fabricated from laminated strand lumber board 5.625″ deep and 1.5″ thick.

B. Partitioned Wall Components

Referring toFIG. 2, structure150has two opposing wall components200, where one of the two opposing wall components200comprises first wall portion200s-1and second wall portion200s-2, and the other of the two opposing wall components200comprises third wall portion200s-3and fourth wall portion200s-4. Each of wall portions200s-1,200s-2,200s-3and200s-4has a generally rectangular planar structure. As shown inFIG. 2, the interior vertical edge192-1of wall portion200s-1is proximate to a respective interior vertical edge192-2of wall portion200s-2, and the interior vertical edge194-3of wall portion200s-3is proximate a respective interior vertical wall edge194-4of wall portion200s-4. Interior edge reinforcement can be provided at any one or more of vertical edges192-1,192-2,194-3and194-4. In the embodiment shown inFIGS. 1 through 6, the interior edge reinforcement provided at vertical edges192-1,192-2,194-3and194-4is fabricated from laminated strand lumber board 5.625″ deep and 1.5″ thick.

Referring again toFIG. 2, first wall portion200s-1is fixed in position on floor portion300aproximate to first transverse edge108, and third wall portion200s-3is fixed in position on floor portion300a,opposite first wall portion200s-1and proximate to second transverse edge110. First wall portion200s-1is joined to second wall portion200s-2with a hinge structure that permits wall portion200s-2to pivot about vertical axis192between a folded position and an unfolded position, and third wall portion200s-3is joined to fourth wall portion200s-4with a hinge structure to permit fourth wall portion200s-4to pivot about vertical axis194between a folded position and an unfolded position.

Notably, first wall portion200s-1is longer than third wall portion200s-3by a distance approximately equal to the thickness of wall component200, and second wall portion200s-2is shorter than fourth wall portion200s-4by a distance approximately equal to the thickness of wall component200. Furthermore, wall portion200s-1and wall portion200s-3are each shorter in length (the dimension in the transverse direction) than the dimension of floor portion300ain the transverse direction. Dimensioning the lengths of wall portions200s-1,200s-2,200s-3and200s-4in this manner permits wall portions200s-2and200s-4to nest against each other in an overlapping relationship when in an inwardly folded position. In this regard,FIG. 2depicts wall portions200s-2and200s-4both in their unfolded positions, where they are labelled200s-2uand200s4-urespectively, andFIG. 2also depicts wall portions200s-2and200s-4both in their inwardly folded positions, where they are labelled200s-2fand200s4-frespectively. When wall portions200s-2and200s-4are in their inwardly folded positions (200s-2fand200s-4f), they facilitate forming a compact shipping module. When wall portion200s-2is in its unfolded position (200s-2u), it forms with wall portion200s-1a wall component200proximate first transverse edge108, and when wall portion200s-4is in its unfolded position (200s-4u), it forms with wall portion200s-3a wall component200proximate second transverse edge110.

The hinge structures referenced for securing first wall portion200s-1to second wall portion200s-2, and third wall portion200s-3to fourth wall portion200s-4, can be surface mounted or recessed, and of a temporary or permanent nature. The provision of interior edge reinforcement, as described above, can provide a region for securing hinge structures. Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material.

As compared to the two wall components200proximate first and second transverse edges108and110, which are partitioned into wall portions, the remaining two wall components200proximate first and second longitudinal edges106and116do not comprise plural wall portions, but rather each is a single piece structure. However, one of these wall components200, which is sometimes denominated200P in this disclosure, and which is located on floor portion300bproximate first longitudinal edge106, is pivotally secured to floor portion300bto permit wall component200P to pivot about horizontal axis105shown inFIG. 3from a folded position to an unfolded position. Pivotally securing wall component200P also facilitates forming a compact shipping module100. The remaining wall component200, sometimes denominated200R in this disclosure, is rigidly secured on floor portion300aproximate second longitudinal edge116and abutting the vertical edges of first wall portion200s-1and third wall portion200s-3proximate to second longitudinal edge116, as shown inFIG. 2.

The hinge structures described above, for securing wall component200P to floor portion300b,can be surface mounted or recessed, and of a temporary or permanent nature. The provision of exterior edge reinforcement, as described above, can provide a region for securing hinge structures. Suitable hinge structures can be fabricated for example of metal, plastic, leather, ferrous or non-ferrous material.

D. Wall Component Appurtenances

Certain appurtenances can be fitted to wall components200to facilitate fastening them to floor component300(described below), as well as to improve the interior appearance and speed fabrication.

As a first appurtenance that can be fitted to wall components200,FIGS. 8A-8Cdepict a toe screw housing288, whose principal components comprise a bearing plate292, a toe screw well289and a toe screw support221. Bearing plate292is a planar plate of a select thickness having a rectangular perimeter, and includes an exterior face293, an opposed interior face294and a top, bevel edge297. Toe screw well289comprises a semi-cylindrical wall298having an axial centerline198, shown inFIG. 8C, which is oriented at an angle (pi from a line normal to the interior face294of bearing plate292. Angle φ1can be in the range of forty-five) (45°) to seventy (70°) degrees, such as sixty (60°) degrees. The exterior face293of bearing plate292defines an aperture that renders the interior volume of toe screw well289accessible from the exterior face side of toe screw well289.

An upper portion of semi-cylindrical wall298is angularly sectioned, for example at an angle of ninety degrees (90°) minus φ1, relative to axial centerline198, for example in the range of forty-five (45°) to twenty (20°) degrees, such as thirty (30°) degrees, with the upper portion so sectioned joined to interior face294. A lower portion of semi-cylindrical wall298is further sectioned parallel to axial centerline198, with each of the resultant two axially-oriented edges joined to a respective triangular gusset299. The two gussets229are spatially opposed and joined to the interior face294of bearing plate292. Toe screw well289also includes a fastener shelf239, visible inFIG. 8A, which is joined to semi-cylindrical wall298and each of the two gussets299. The interior volume of toe screw well289, which is defined by fastener shelf239, gussets299and semi-cylindrical wall298, forms a recess within toe screw well289for receiving a fastener head. Fastener shelf239has a planar upper face that is perpendicularly oriented to the axial centerline198of semi-cylindrical surface298, and a planar opposed lower face that is perpendicularly oriented to the axial centerline198of semi-cylindrical surface298. It should be noted that the upper face of fastener shelf239will correspondingly be oriented at angle (pi relative to interior face294and exterior face293.

The lower face of fastener shelf239is joined to a toe screw support221. Toe screw support221comprises a semi-cylindrical solid222and a triangular wedge223. Semi-cylindrical solid222has an axial centerline197, shown inFIG. 8C, which is oriented at an angle φ2from a line normal to the interior face294of bearing plate292. Angle φ2can be in the range of forty-five (45°) to seventy (70°) degrees, such as sixty (60°) degrees, and preferably φ1equals φ2. Centerlines197and198can be, but need not be, co-linear. The upper portion of semi-cylindrical solid222is sectioned normal to axial centerline197, with the sectioned portion joined to the lower face of fastener shelf239, and is further sectioned parallel to axial centerline197and joined to triangular wedge223. In turn, the upper surface of wedge223is joined to the lower face of fastener shelf239, and wedge223is further joined at its narrow end to the interior face294of bearing plate292. The diameter of semi-cylindrical solid222is less than the diameter of semi-cylindrical wall298, in the embodiment shown inFIGS. 8A-8C.

Toe screw support221also includes a support surface224defined by the lower surfaces of semi-cylindrical solid222and wedge223. Support surface224is perpendicularly oriented to the interior face294of bearing plate292. A groove199is cut into the planar lower surface of support surface224. Groove199is oriented parallel to the interior face294of bearing plate292, and, in the embodiment shown in the figures, is spaced from interior face294a distance approximately equal to the thickness of protective layer218.

A fastener bore225passes through fastener shelf239and toe screw support221, with an exit orifice in support surface224, thereby forming a passage through toe screw support221for a fastener, the head of which can be positioned against the upper face of fastener shelf239. Preferably, the axial centerline of fastener bore225is co-linear with the axial centerline197of semi-cylindrical wall222, so that the axial centerline of fastener bore225is not perpendicular to the exterior face293of bearing plate292, but rather is oriented at angle φ2from a line normal to the exterior face293of bearing plate292.

Bevel edge297of toe screw housing288forms an angle φ3with exterior face293to provide a sloped bevel surface between the end of bevel edge297and interior face294of bearing plate292. Accordingly, angle φ3is not perpendicular to the exterior face293of bearing plate292, but rather is an acute angle, such as forty-five degrees (45°) or less, and in particular twenty degrees (20°).

As a second appurtenance that can be fitted to wall components200,FIGS. 9A-9Cdepict an interior baseboard140. Interior baseboard140is a planar elongate member with a planar elongate exterior face141, a planar elongate interior face142, an elongate top edge143and an elongate bottom edge144. An elongate hook ledge145is joined along the top edge143of interior baseboard140and forms a downward facing wedge-shaped angled slot146that has an interior angle φ4, shown inFIG. 9C, which is preferably the same as angle φ3of bevel edge297, or nearly so. Interior face142has an elongate linear first step147positioned below angled slot146, so as to define an elongate bearing plate recess148between angled slot146and first step147sufficiently wide to receive bearing plate292. Positioned below first step147, interior face142has an elongate linear second step137that extends a distance from bottom edge144, so as to define a fastening recess138between first step147and second step138.

For wall components200utilizing the laminate design shown inFIG. 7, a plurality of toe screw housings288can be fastened at space-apart intervals in proximity to the bottom of the wall components200, as shown inFIG. 10C. As shown inFIG. 10A, each toe screw housing288is positioned so that the support surface224of its toe screw support221rests upon the floor plate220of the wall component200. Select portions of the foam panel layer213, sheet metal layer216and protective layer218are removed to provide a space to receive the toe screw well289and toe screw support221of the toe screw housing288, and so that the interior face294of bearing plate292of the toe screw housing288lies against protective layer218. As described above, the distance from groove199to interior face294of bearing plate292is approximately equal to the thickness of protective layer218. When so dimensioned, groove199can engage the edge of sheet metal layer216immediately below the removed portion thereof, as shown inFIG. 10A.

Plural toe screw housings288can be utilized to fasten both partitioned and unpartitioned wall components200to floor component300(described below). For example, referring toFIGS. 10B and 10C, toe screw housings288are shown being utilized in connection with both wall portion200s-4and wall component200P. Following their unfolding (described below), a fastener, such as a SIP screw136can be inserted into fastener bore225, as illustrated inFIG. 10A, and driven into the exterior edge reinforcement of both the wall component200and the underlying floor component300, specifically floor plate220and footing beam320respectively, as shown inFIG. 10B, to fasten the wall component200to the floor component300.

Plural toe screw housings288can also be utilized to fasten each of fixed wall component200R, fixed wall portion200s-1, fixed wall portion200s-3and pivoting wall portion200s-2to floor component300. In the case of wall component200R and fixed wall portions200s-1and200s-3, the fastening operation just described can be undertaken during factory fabrication of fixed space portion102, described further below.

In using toe screw housings288to fasten wall component200P to floor section300b,it can be seen inFIG. 10Bthat one or more screws136will also pass through two sealing structures, wall end cap246and floor top plate252, which are present at the junction of wall component200P and floor portion300b.A similar sealing structure arrangement is present in the cases of the junction between wall component200R and floor portion300a,the junction between fixed wall portion200s-1and floor portion300a,and the junction between wall portion200s-3and floor component300a.A more detailed description of these sealing structures is set forth in PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as the present application, for example in0092, 0097-0101 and 0112-0120, and in connection with FIGS. 12 and 15, of that application. The contents of that PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as this disclosure, are incorporated by reference as if fully set forth herein, particularly including the wall end cap 246 and floor top plate 252 described for example at0092, 0097-0101 and 0112-0120, and in connection with FIGS. 12 and 15, of that application.

In using toe screw housings288to fasten wall portions200s-2and200s-4to floor portions300aand300b,one or more screws136will also pass through sealing structures that are present at the junction of pivoting wall portion200s-2in its unfolded position and floor portions300a/300b,and at the junction of pivoting wall portion200s-4in its unfolded position and floor portions300a/300b.However, these sealing structures, namely wall end interlock A262(not shown) and floor top interlock261(not shown), differ from wall end cap246and floor top plate252, in that they are designed to permit the lateral movement of wall portions200s-2and200s-4relative to floor portions300aand300b.A more detailed description of these sealing structures is set forth in PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as the present application, for example in0136-0147 and in connection with FIG. 17 thereof. The contents of that PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as this disclosure, are incorporated by reference as if fully set forth herein, particularly including the wall end interlock A 262 and floor top interlock 261 described for example at0136-0147 and in connection with FIG. 17 thereof.

After the fasteners are driven into the toe screw housings288, the housings can be masked from view by placing an interior baseboard140of an appropriate length over the toe screw housings, as shown inFIG. 10A. The size of interior baseboard288can be adjusted prior to installation to accommodate flooring finishes of different types. For this reason, the interior face142is provided with a first elongate linear notch149(seeFIGS. 9B, 9C) above bottom edge144a sufficient distance to indicate the cut line for accommodating thin flooring, such as floor tiles, and a second elongate linear notch139(seeFIGS. 9B, 9C), above notch149a sufficient distance to indicate the cut line for accommodating thicker flooring, such as hardwood flooring.

In use, the hook ledge145of interior baseboard140engages the bevel edge297of the toe screw housings288positioned along the bottom of the wall component200, which thus facilitates the rapid and accurate placement of interior baseboard140. The interior baseboard140can be secured in place by providing for example hook-and-loop fasteners, or adhesive material, in the fastening recess138of the interior baseboard140. Toe screw housings288and interior baseboard140can be made from aluminum, plastics and the like. It is preferred to fabricate the toe screw housing288and interior baseboard140from foamed polyvinyl chloride (PVC), particularly Celuka foamed PVC.

Floor Component (300)

Typically, structure150will utilize one floor component300; thus floor component300generally is the full floor of structure150.

A. General Description

Floor component300has a generally rectangular perimeter.FIGS. 4 and 5depict edge-on views of floor component300in accordance with the present inventions. The perimeter of floor component300is defined by first longitudinal floor edge117, first transverse floor edge120, second longitudinal floor edge119and second transverse floor edge118. In particular, (a) first longitudinal floor edge117, (b) first transverse floor edge120, (c) second longitudinal floor edge119and (d) second transverse floor edge118generally coincide with (i.e., underlie) (w) first longitudinal edge106, (x) first transverse edge108, (y) second longitudinal edge116and (z) second transverse edge110, respectively, of structure150.

The length and width of floor component300can vary in accordance with design preference. In the particular embodiment of structure150depicted inFIGS. 2, 4 and 5, floor component300is approximately 19 feet (5.79 m) by 19 feet (5.79 m).

Floor component300and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which floor component300may be subject. It is preferred that floor component300utilize a multi-layered, laminate design, such as that described in connection withFIG. 7. In the embodiment shown inFIGS. 4 and 5, the bottom-most surface of floor component300comprises sheet metal layer205of first structural layer210, with sheet metal layer205being24gauge galvanized steel approximately 0.022-0.028 inch thick. Above sheet metal layer205there are provided foam panels214of foam panel layer213. In the embodiments shown inFIGS. 4 and 5, foam panels214are EPS foam for example approximately 7.125 inches thick.

Above foam panel layer213there is provided sheet metal layer216of second structural layer215, with sheet metal layer216being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Above sheet metal layer216of second structural layer215, there are provided building panels219of protective layer218, with building panels219being MgO board approximately 0.25 inch (6 mm) thick.

The perimeter of each floor component300is generally provided with exterior edge reinforcement. As exterior edge reinforcement for the embodiments of floor component300shown inFIGS. 4 and 5, a first footing beam320(visible edge-on inFIG. 4) is positioned at the first longitudinal floor edge117of floor component300, a second footing beam320(visible edge-on inFIG. 5) is positioned at the second transverse floor edge118of floor component300, a third footing beam320(visible edge-on inFIG. 5) is positioned at the first transverse floor edge120of floor component300, and a fourth footing beam320(visible edge-on inFIG. 4) is positioned at the second longitudinal floor edge119of floor component300. In the case of floor component300, the exterior edge reinforcement provided by footing beams320assists in resisting vertical loads and transferring such loads to any roof component400thereunder and then to underlying wall components200, and/or to the foundation of the finished structure150, in addition to protecting the edges of foam panel material. In the embodiment shown inFIGS. 1 through 6, the exterior edge reinforcement provided by footing beams420of floor component300is fabricated from laminated strand lumber board 7.125″ deep and 1.5″ thick.

Each of the floor portions300aand300bis a planar generally rectangular structure, with floor portion300aadjoining floor portion300b.Interior edge301aof floor portion300aabuts interior edge301bof floor portion300b,as shown inFIG. 4. As interior edge reinforcement, a reinforcing board307is positioned in floor portion300aadjacent interior edge301a,and a reinforcing board is positioned in floor portion300badjacent interior edge301b.In the embodiment show in inFIGS. 1 through 5, the interior edge reinforcement provided by reinforcing boards307is made of laminated strand lumber laminated strand lumber board

Referring to structure150shown inFIGS. 2 and 4, floor portion300ais fixed in position relative to first wall portion200s-1, third wall portion200s-3and wall component200s-R. Floor portion300ais joined with hinge structures to floor portion300b,so as to permit floor portion300bto pivot through approximately ninety degrees (90°) of arc about a horizontal axis305, located proximate the top surface of floor component300, between a fully folded position, where floor portion300bis vertically oriented as shown inFIG. 3, and the fully unfolded position shown inFIGS. 2 and 4, where floor portion300bis horizontally oriented and co-planar with floor portion300a.Particular embodiments of structural members that incorporate hinge structures suitable to join floor portion300ato floor portion300bare described in in U.S. Nonprovisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as this disclosure. The contents of that U.S. Nonprovisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as this disclosure, is incorporated by reference as if fully set forth herein, particularly the description of the hinged load transfer components set forth for example in0074-0089 and in FIGS. 8A-13E thereof, as well as the description of the associated end hinge assemblies set forth for example in0090-0093and in FIGS. 14A-14B thereof.

Roof Component (400)

Typically, structure150will utilize one roof component400; thus roof component400generally is the full roof of structure150.

A. General Description

Roof component400has a generally rectangular perimeter.FIGS. 1, 4 and 5depict roof component400in accordance with the present inventions. The perimeter of roof component400is defined by first longitudinal roof edge406, first transverse roof edge408, second longitudinal roof edge416and second transverse roof edge410. In particular, (a) first longitudinal roof edge406, (b) first transverse roof edge408, (c) second longitudinal roof edge416and (d) second transverse roof edge410of roof component400generally coincide with (i.e., overlie) (w) first longitudinal edge106, (x) first transverse edge108, (y) second longitudinal edge116and (z) second transverse edge110, respectively, of structure150.

The length and width of roof component400can vary in accordance with design preference. In the particular embodiment of structure150depicted inFIGS. 1, 4 and 5, the length and width of roof component400approximates the length and width of floor component300.

Roof component400and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which roof component400may be subject. It is preferred that roof component400utilize a multi-layered, laminate design, such as that described in connection withFIG. 7. In the embodiment shown inFIGS. 4 and 5, the top-most surface of roof component400comprises sheet metal layer205of first structural layer210, with sheet metal layer205being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Below sheet metal layer205there are provided foam panels214of foam panel layer213, with foam panels214in the embodiment shown inFIGS. 4 and 5being EPS foam for example approximately 7.125 inches thick. Below foam panel layer213there is provided sheet metal layer216of second structural layer215, with sheet metal layer216being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Below sheet metal layer216of second structural layer215, there are provided building panels219of protective layer218, with building panels219being MgO board approximately 0.25 inch (6 mm) thick.

The perimeter of roof component400is generally provided with exterior edge reinforcement. As exterior edge reinforcement for the embodiment of roof component400shown inFIGS. 4 and 5, a first shoulder beam435(visible edge-on inFIG. 4) is positioned at the first longitudinal roof edge406of roof component400, a second shoulder beam435(visible edge-on inFIG. 5) is positioned at the first transverse roof edge408of roof component400, a third shoulder beam435(visible edge-on inFIG. 5) is positioned at the second transverse roof edge410of roof component400, and a fourth shoulder beam435(visible edge-on inFIG. 4) is positioned at the second longitudinal roof edge416of roof component400. In addition to protecting the exterior edges of foam panel material, the exterior edge reinforcement provided by shoulder beams435assists in resisting vertical loads and transferring such loads to lower floors through underlying wall components200supporting roof component400, and then to the foundation of the structure150. Such exterior edge reinforcement can also provide a region for fastening like regions of abutting enclosure components155(underlying and any overlying). Shoulder beams435of roof component400can be fabricated from laminated strand lumber board 7.125″ deep and 1.5″ thick.

Each of the roof portions400a,400band400cis a planar generally rectangular structure, with roof portion400aadjoining roof portion400b,and roof portion400badjoining roof portion400c.Interior edge412cof roof component400cabuts a first interior edge412bof roof component400b,as shown inFIG. 4. For interior edge reinforcement, a reinforcing board437is positioned adjacent interior edge412c,and a reinforcing board437is positioned against first interior edge412b.Interior edge412aof roof portion400aabuts a second interior edge412bof roof portion400b,as shown inFIG. 4. For interior edge reinforcement, a reinforcing board437is positioned adjacent interior edge412a,and a reinforcing board437is positioned against second interior edge412b.In the embodiment shown inFIGS. 1through5, the interior edge reinforcement provided by reinforcing boards437of roof component400is laminated strand lumber board 7.125″ deep and 1.5″ thick.

In the shipping module100shown inFIG. 3, roof portions400a,400band400cpreferably are accordion folded (stacked), with roof component400bstacked on top of roof component400a,and roof component400cstacked on top of the roof component400b.Referring to structure150shown inFIG. 4, roof portion400ais fixed in position relative to first wall portion200s-1, third wall portion200s-3and wall component200R. Thus to realize the accordion folded configuration shown inFIG. 3roof portion400ais joined to roof portion400bwith hinge structures provided between interior edge412aof roof portion400aand second interior edge412bof roof portion400b.Such hinge structures are adapted to permit roof portion400bto pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis405a,located proximate the top of roof component400and shown inFIG. 4, between the roof fully folded position shown inFIG. 3, where roof portion400blies stacked flat against roof portion400a,and the fully unfolded position shown inFIG. 4. In turn, roof portion400bis joined to roof portion400cwith hinge structures provided between first interior edge412bof roof portion400band interior edge412cof roof portion400c.Such hinge structures are adapted to permit roof portion400cto pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis405b,located proximate the bottom of roof component400and shown inFIG. 4, between the folded position shown inFIG. 3, where roof portion400clies stacked flat against roof portion400b(when roof portion400bis positioned to lie flat against roof portion400a), and the fully unfolded position shown inFIG. 4.

Particular embodiments of structural members, which also incorporate hinge structures suitable for joining roof portion400ato roof portion400b,and for joining roof portion400bto roof portion400c,are described in in U.S. Nonprovisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as this disclosure. The contents of that U.S. Nonprovisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as this disclosure, is incorporated by reference as if fully set forth herein, particularly the description of the load transfer components set forth for example in0104-0126 and in FIGS. 15A-24A thereof, as well as the description of the associated end hinge assemblies set forth for example in0127-0132 and in FIGS. 24B and 25A-25D thereof.

Enclosure Component Manufacture

For enclosure components155utilizing the multi-layered, laminate design disclosed herein in reference toFIG. 7, the metal sheets206and217that can be used to form first structural layer210and second structural layer215respectively can be entirely flat and juxtaposed in a simple abutting relationship. Optionally, metal sheets206and217can be provided with edge structures that facilitate placement of sheets and panels during manufacture.

Particular edge structure designs for metal sheets206and217are described in U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 19, 2021. The contents of U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 19, 2021, are incorporated by reference as if fully set forth herein, particularly including the exterior and interior edge structure designs described for example at00187-00205 and 00212 and in FIGS. 8, 9A-9C, 23A-23J and 24A-24B thereof.

A facility suitable for the manufacture of enclosure components155, as well as exemplary manufacturing steps, are also described in U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 19, 2021. The contents of U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 19, 2021, are incorporated by reference as if fully set forth herein, particularly including the facility suitable for manufacturing the enclosure components155of the present invention, as well as exemplary manufacturing steps, described for example at00178-00186 and 00206-00222, and in FIGS. 22, 23A-23J and 24A-24B.

Fixed Space Portion Build-Out and Finishing

Referring toFIGS. 2 and 10A-10C, structure150includes a fixed space portion102defined by roof component400a(shown inFIG. 3), floor component300a,wall component200R, wall portion200s-1and wall portion200s-3. (Fixed space portion102is also shown edge-on in the shipping module100depicted inFIG. 3). It is preferred that the fixed space portion102be fitted out during manufacture with internal components, such as kitchens, bathrooms, closets, storage areas, corridors, etc., so as to be in a relatively finished state prior to shipment of shipping module100.

For example, interior partition walls as desired can be put into fixed space portion102during manufacture. Referring toFIGS. 2 and 10A-10C, there is shown a longitudinal partition wall126and a transverse partition wall127. Partition walls126and127each can comprise a foam panel layer, for example three inches (3″) thick, with building panels such as magnesium oxide (MgO) board approximately 0.25 inch (6 mm) thick fastened to each face of the foam panel using a suitable adhesive, preferably a polyurethane based construction adhesive.

As shown for example inFIG. 11A, a first vertical edge of longitudinal partition wall126abuts wall portion200s-1, and a first vertical edge of transverse partition wall127abuts wall component200R. The second vertical edge of transverse wall portion127abuts the longitudinal partition wall126proximate to the latter's second vertical edge, such that partition walls126and127, with wall component200R and wall portion200s-1, form a rectangular enclosed area that, in the embodiment shown inFIGS. 2 and 11A-11C, is a bath room128. In the embodiment shown, bath room128is fitted out during manufacture to include a shower enclosure, a toilet and a wash sink.

The open area between transverse partition wall127and wall portion200s-3in the embodiment shown inFIGS. 2 and 11A-11Cis a kitchen area129. In the embodiment shown inFIGS. 11A-11C, kitchen area129is fitted out during manufacture to include cabinets, countertops and cooking facilities.

Also, in the embodiment shown inFIGS. 1 and 2, wall components200are fitted during manufacture and prior to shipment with all necessary door and window assemblies, with the enclosure components155being pre-wired for electrical needs.

Carrying out the foregoing steps prior to shipment permits the builder, in effect, to erect a largely finished structure simply by “unfolding” (deploying) the positioned components of shipping module100.

Enclosure Component Relationships and Assembly for Transport

It is preferred that there be a specific dimensional relationship among enclosure components155.

FIG. 2shows a top schematic view of structure150shown inFIG. 1, and includes a geometrical orthogonal grid for clarity of explaining the preferred dimensional relationships among its enclosure components155. The basic length used for dimensioning is indicated as “E” inFIG. 2; the orthogonal grid overlaid inFIG. 2is 8E long and 8E wide; notably, the entire structure150preferably is bounded by this 8E by 8E orthogonal grid.

Roof portions400a,400band400ceach can be identically dimensioned in the transverse direction. Alternatively, referring toFIG. 3, roof portion400ccan be dimensioned to be larger than either of roof portion400aand roof portion400bin the transverse direction to reduce the chances of binding during the unfolding of roof portions400b,400c.Further specifics on dimensioning roof portion400cin the foregoing manner are described in U.S. Nonprovisional application Ser. No. 17/569,962, entitled “Improved Folding Roof Component,” filed on Jan. 6, 2022. In addition, as described in U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” filed on Feb. 10, 2020 and now U.S. Pat. No. 11,220,816, as well as in U.S. Nonprovisional application Ser. No. 17/569,962 mentioned above, friction-reducing components can be used to facilitate unfolding roof component400, such as by positioning a first wheel caster at the leading edge of roof portion400cproximate to the corner of roof portion400cthat is supported by wall portion200s-2as roof portion400cis deployed, and by positioning a second similar wheel caster at the leading edge of roof portion400cproximate to the corner of roof portion400cthat is supported by wall portion200s-4as roof portion400cis deployed.

InFIG. 2, the four wall components200are each approximately 8E long, and each of roof portions400aand400bis approximately 8E long and 2.5E wide. Roof portion400cis approximately 8E long and 2.9E wide. InFIGS. 2 and 3, each of floor components300aand300bis 8H long; whereas floor component300ais just over 3E wide and floor component300bis just under 5E wide.

As shown inFIG. 2, fourth wall portion200s-4is folded inward and positioned generally against fixed space portion102, and second wall portion200s-2is folded inward and positioned generally against fourth wall portion200s-4(wall portions200s-2and200s-4are respectively identified inFIG. 2as portions200s-2fand200s-4fwhen so folded and positioned). The three roof components400a,400band400care shown unfolded inFIG. 1and shown folded (stacked) inFIG. 3, with roof component400bstacked on top of roof component400a,and roof component400cstacked on top of the roof component400b.Wall component200P, shown inFIGS. 2 and 3, is pivotally secured to floor portion300bat the location of axis105, and is vertically positioned against the outside of wall portions200s-2and200s-4. In turn, floor portion300bis vertically positioned proximate fixed space portion102, with wall component200P pending from floor portion300bbetween floor portion300band wall portions200s-2and200s-4.

Sizing the enclosure components155of structure150according to the dimensional relationships disclosed above yields a compact shipping module100, as can be seen from the figures. Thus shipping module100depicted inFIG. 3, when dimensioned according to the relationships disclosed herein using an “E” dimension (seeFIG. 2) of approximately 28.625 inches (72.7 cm), and when its components are stacked and positioned as shown inFIG. 3, has an overall length of approximately 19 feet (5.79 m), an overall width of approximately 8.5 feet (2.59 meters) and an overall height of approximately 12.7 feet (3.87 meters). These overall dimensions are less than a typical shipping container.

Each of the wall, floor and roof components200,300and400, and/or the portions thereof, can be sheathed in protective film177during fabrication and prior to forming the shipping module100. Alternatively or in addition, the entire shipping module100can be sheathed in a protective film. Such protective films can remain in place until after the shipping module100is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.

Shipping Module Transport

The shipping module100is shipped to the building site by appropriate transport means. One such transport means is disclosed in U.S. Nonprovisional application Ser. No. 16/143,628, filed Sep. 27, 2018 and now U.S. Pat. No. 11,007,921, issued May 18, 2021; the contents of that U.S. Nonprovisional application Ser. No. 16/143,628, filed Sep. 27, 2018 are incorporated by reference as if fully set forth herein, particularly as found at paragraphs 0020-0035 and in FIGS. 1A-2D thereof. As an alternative transport means, shipping module100can be shipped to the building site by means of a conventional truck trailer or a low bed trailer (also referred to as a lowboy trailer), and in the case of over-the-water shipments, by ship.

Structure Deployment and Finishing

At the building site, shipping module100is positioned over its desired location, such as over a prepared foundation; for example, a poured concrete slab, a poured concrete or cinder block foundation, sleeper beams or concrete posts or columns. This can be accomplished by using a crane, either to lift shipping module100from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module100, then moving the transport means from the desired location, and then lowering shipping module100to a rest state at the desired location. Particularly suitable equipment and techniques for facilitating the positioning of a shipping module100at the desired location are disclosed in U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, now U.S. Pat. No. 11,220,816. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at126-128 and in connection with FIGS. 11A and 11B thereof.

Following positioning of shipping module100at the building site, the appropriate portions of wall, floor and roof components200,300and400are “unfolded” (i.e., deployed) to yield structure150. Unfolding occurs in the following sequence: (1) floor portion300bis pivotally rotated about horizontal axis305(shown inFIGS. 3 and 4) to an unfolded position, (2) wall component200P is pivotally rotated about horizontal axis105(the general location of which is shown inFIG. 3) to an unfolded position, (3) wall portions200s-2and200s-4are pivotally rotated about vertical axes192and194(shown inFIG. 2) respectively to unfolded positions, and (4) roof portions400band400care pivotally rotated about horizontal axes405aand405b(shown inFIGS. 3 and 4) respectively to unfolded positions.

A mobile crane can be used to assist in the deployment of certain of the enclosure components155, specifically roof portions400band400c,floor portion300b,as well as the wall component200P pivotally secured to floor portion300b.Alternatively, particularly suitable equipment and techniques for facilitating the deployment of enclosure components155are disclosed in U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, now U.S. Pat. No. 11,220,816. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at132-145 and depicted in FIGS. 12A-14B thereof.

After unfolding, the enclosure components155are secured together to finish the structure150that is shown inFIG. 1. If any temporary hinge structures have been utilized, then these temporary hinge structures can be removed if desired and the enclosure components155can be secured together. During or after unfolding and securing of the enclosure components155, 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 structure150, as relevant here.

This disclosure should be understood to include (as illustrative and not limiting) the subject matter set forth in the following numbered clauses:

Clause 1. A toe screw housing for securing abutting enclosure components together, comprising:

a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face;

a toe screw well joined to and extending away from the interior face and including a fastener shelf;

a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and

a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate.

Clause 2. The toe screw housing of clause 1, further including a groove formed in the support surface oriented parallel to the interior face.

Clause 3. The toe screw housing of either of clause 1 or clause 2, wherein the second angle is in the range of forty-five degrees (45°) to seventy degrees (70°).

Clause 4. The toe screw housing of any one of clause 1, 2 or 3, where the second angle is sixty degrees (60°).

Clause 5. The toe screw housing of any one of clause 1, 2, 3 or 4, where the first angle is less than forty-five degree (45°).

Clause 6. The toe screw housing of any one of clause 1, 2, 3, 4 or 5, where the first angle is twenty degrees (20°).

Clause 7. A baseboard for masking a toe screw bearing plate having a beveled upper edge, comprising:

a planar elongate member having an elongate interior face, an elongate top edge and an elongate bottom edge;

an elongate hook ledge joined to the top edge of the base board forming a wedge-shaped angled slot that is oriented to be open in the direction of the bottom edge, the wedge-shaped angled slot configured to be positioned over the beveled upper edge of the bearing plate;

an elongate linear first step positioned on the interior face below the angled slot to form an elongate first recess on the interior face configured to receive the toe screw bearing plate; and

an elongate second step positioned on the interior face below the elongate first step to form an elongate second recess on the interior face.

Clause 8. A baseboard as in clause 7, further comprising a first elongate linear notch in the second step a first select distance above the bottom edge.

Clause 9. A baseboard as in either of clause 7 or clause 8, further comprising a second elongate linear notch in the second step a second select distance above the bottom edge that is greater than the first select distance.

Clause 10. A system for securing abutting enclosure components together, comprising:

(a) a toe screw housing that includes:

(i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face;

(ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf;

(iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and

(iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and

(b) a planar elongate base board having an elongate top edge and an elongate bottom edge and including;

(i) an elongate hook ledge joined to the top edge of the base board, the hook ledge positioned over the beveled upper edge of the bearing plate; and

(ii) an elongate linear first step positioned on the interior face below the angled slot to form an elongate first recess on the interior face in which is positioned the toe screw bearing plate.

Clause 11. The system of claim 10, further comprising (iii) an elongate second step positioned on the interior face of the base board below the elongate first step to form an elongate second recess on the interior face.

Clause 12. A wall component comprising:

(a) a foam panel layer having a first face and an opposing second face;

(b) a metal sheet layer having a first face, an opposing second face, with the first face of the metal sheet layer being bonded to the opposing second face of the foam panel layer; and

(c) a protective layer having a first face, an opposing second face, with the first face of the protective layer being bonded to the opposing second face of the sheet metal layer;

(d) an elongate external edge reinforcement abutting the foam panel layer;

(e) a plurality of toe screw housings, each of the plurality of toe screw housings comprising:

(i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face;

(ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf;

(iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and

(iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and

(f) the toe screw well and toe screw support of each toe screw housing positioned in a respective one of a plurality of spaced-apart apertures passing through the protective layer and the metal sheet layer, and in a respective one of a plurality of corresponding cavities formed in the foam panel layer, with the planar support surface of the toe screw support of each of the plurality of toe screw housings positioned against the external edge reinforcement and with the interior face of the bearing plate positioned against the protective layer

Clause 13. A folded building structure transportable to a site at which the folded building structure is to be erected, comprising:

a fixed space portion defined by (i) a first floor portion having an edge reinforcement along a first outside edge and an edge reinforcement segment along an adjacent second outside edge, (ii) a first wall component having an edge reinforcement along a first bottom edge positioned on the first floor portion proximate the first outside edge, and (iii) a planar fixed wall portion of a second wall component having an edge reinforcement segment along a second bottom edge positioned on the first floor portion proximate the second outside edge;

a second floor portion vertically positioned in a second floor portion folded position opposite to the first wall component and pivotally connected to the first floor portion to permit the second floor portion to pivot, about a first horizontal axis relative to the first floor portion, from the second floor portion folded position to a second floor portion unfolded position, the second floor portion having an edge reinforcement along a third outside edge distal from the first horizontal axis and an edge reinforcement segment along an adjacent fourth outside edge;

a third wall component vertically positioned in a third wall component folded position against the second floor portion, the third wall component pivotally connected to the second floor portion to permit the third wall portion to pivot, about a second horizontal axis relative to the second floor portion, from the third wall component folded position to a third wall component unfolded position, the third wall component having an edge reinforcement along a third bottom edge positioned on the second floor portion proximate to the third outside edge when the second floor portion is in the second floor portion unfolded position and the third wall component is in the third wall component unfolded position;

the second wall component additionally including a planar pivoting wall portion having an edge reinforcement segment along a fourth bottom edge, the pivoting wall portion (i) disposed in a pivoting portion folded position proximate the fixed space portion, and (ii) pivotally connected to the fixed wall portion of the second wall component to permit the pivoting wall portion to pivot, about a vertical axis relative to the fixed wall portion of the second wall component, from the pivoting portion folded position to a pivoting portion unfolded position in which at least a portion of the fourth bottom edge is positioned on the second floor portion proximate to the fourth outside edge when the second floor portion is in the second floor portion unfolded position and the pivoting wall portion is in the pivoting portion unfolded position;

a first plurality of toe screw housings having a spaced-apart relationship, each of the first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and

the toe screw well and toe screw support of at least a first of the first plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the pivoting wall portion and with its support surface against the edge reinforcement segment along the fourth bottom edge of the pivoting wall portion.

Clause 14. A folded building structure as in clause 13, further comprising a second plurality of toe screw housings having a spaced-apart relationship, each of the second plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and the toe screw well and toe screw support of each of the second plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the third wall component and with its support surface against the edge reinforcement along the third bottom edge of the third wall component.

Clause 15. A folded building structure as in either of clause 13 or clause 14, further comprising a third plurality of toe screw housings having a spaced-apart relationship, each of the third plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate;

the toe screw well and toe screw support of each of the third plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the first wall component and with its support surface against the edge reinforcement along the first bottom edge of the first wall component; and

a first fastener positioned within at least one of the third plurality of toe screw housings, the first fastener comprising a head in pressing contact with the fastener shelf thereof, and a shank passing through the toe screw well thereof, through the edge reinforcement along the first bottom edge of the first wall component and into the edge reinforcement along the first outside edge of the first floor portion.

Clause 16. A folded building structure as in any one of clause 13. 14 or 15, further comprising a fourth plurality of toe screw housings having a spaced-apart relationship, each of the fourth plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate;

the toe screw well and toe screw support of each of the fourth plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the fixed wall portion and with its support surface against the edge reinforcement segment along the second bottom edge of the fixed wall portion; and

a second fastener positioned within at least one of the fourth plurality of toe screw housings, the second fastener comprising a head in pressing contact with the fastener shelf thereof, and a shank passing through the toe screw well thereof, through the edge reinforcement segment along the second bottom edge of the fixed wall portion and into the edge reinforcement segment along the second outside edge of the first floor portion.

Clause 17. A building comprising:

an interior region defined by (i) a floor portion having an edge reinforcement along a first outside edge and an edge reinforcement segment along an adjacent second outside edge, (ii) a wall component having an edge reinforcement along a first bottom edge positioned on the first floor portion proximate the first outside edge, and (iii) a wall portion having an edge reinforcement segment along a second bottom edge positioned on the first floor portion proximate the second outside edge;

a first plurality of toe screw housings having a spaced-apart relationship, each of the first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and

the toe screw well and toe screw support of each of the first plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the wall component and with its support surface against the edge reinforcement along the first bottom edge of the wall component.

Clause 18. The building of clause 17, further comprising a first interior partition wall abutting one of (i) the inside surface of the wall component and (ii) an inside surface of the wall portion, and extending perpendicularly therefrom.

Clause 19. The building of clause 18, further comprising a second interior partition wall abutting the other of the inside surface of the wall component and the inside surface of the wall portion and extending perpendicularly therefrom to form a junction with the first interior partition wall and thereby define an enclosed interior space.

Clause 20. The building of either of clause 18 or clause 19, wherein the first interior partition wall comprises:

(a) a foam panel layer having a first face and an opposing second face;

(b) a first protective layer having a first face, an opposing second face, with the first face of the first protective layer being bonded to the first face of the foam panel layer; and

(c) a second protective layer having a first face, an opposing second face, with the first face of the second protective layer being bonded to the opposing second face of the foam panel layer.

Clause 21. The building of clause 19, wherein the second interior partition wall comprises:

(a) a foam panel layer having a first face and an opposing second face;

(b) a first protective layer having a first face, an opposing second face, with the first face of the first protective layer being bonded to the first face of the foam panel layer; and

(c) a second protective layer having a first face, an opposing second face, with the first face of the second protective layer being bonded to the opposing second face of the foam panel layer.

Clause 22. The building of either of clause 19 or clause 21, wherein the enclosed interior space includes one or more of a shower enclosure, a toilet and a wash sink.

Clause 23. The building of any one of clause 19, 21 or 22, wherein a portion of the interior region outside the enclosed interior space includes one or more of a cabinet, a countertop and a cooking facility.

Clause 24. The building of any one of clauses 17-23, wherein the first wall component comprises:

(a) a foam panel layer having a first face and an opposing second face;

(b) a metal sheet layer having a first face, an opposing second face, with the first face of the metal sheet layer being bonded to the opposing second face of the foam panel layer; and

(c) a protective layer having a first face, an opposing second face that constitutes the inside surface of the first wall component, with the first face of the protective layer being bonded to the opposing second face of the sheet metal layer; and

(d) the edge reinforcement along the first bottom edge of the first wall component abuts the foam panel layer.

Clause 25. The folded building structure of clause 15, further comprising a planar elongate base board having an elongate top edge and an elongate bottom edge, with an elongate hook ledge joined to the top edge of the base board and positioned over the beveled upper edge of the bearing plate of at least one of the toe screw housings of the third plurality of toe screw housings.

Clause 26. The folded building structure of clause 16, further comprising a planar elongate base board having an elongate top edge and an elongate bottom edge, with an elongate hook ledge joined to the top edge of the base board and positioned over the beveled upper edge of the bearing plate of at least one of the toe screw housings of the fourth plurality of toe screw housings.

The foregoing detailed description is for illustration only and is not to be deemed as limiting the inventions disclosed herein, which are defined in the appended claims.