Folding Beam Systems

Structural beams for a building structure that can be folded, to permit the creation of a compact building structure shipping module. The structural beams also can be unfolded and locked in the unfolded position to provide a rigid structure for resisting vertical loads and transferring them to lower levels and ultimately the building foundation.

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. One of the alternatives to stick-built construction is very generally referred to as modular housing. As opposed to stick-built construction, where the structure is built on-site, a modular house is constructed in a factory and then shipped to the site, often by means of a tractor-trailer.

Such modular housing often exceeds in size normally-permitted legal limits for road transport. For example, in the United States the maximum permitted dimensions for road transport are in general 102 inches (259.1 cm) in width, 13.5 feet (4.11 m) in height and 65 to 75 feet (19.81 to 22.86 m) in length. Thus, in many cases transporting a modular house from factory to site requires oversize load permits, which may impose restrictions on when transport can be undertaken and what routes can be utilized. Oversize road regulations may also require the use of an escort car and a trailing car as well. All of these requirements and restrictions inevitably increase the cost of the modular housing.

Significant advancements in the construction of dwellings and commercial space are described in U.S. Pat. Nos. 8,474,194, 8,733,029, 10,688,906, 10,829,029 and 10,926,689. 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 constitute advancements in transferring vertical loads, such as personnel weight, furniture, equipment and the like, to the edges of horizontally oriented enclosure components, particularly floor components and roof components. These inventions include structural members that can be folded, to permit the creation of a compact shipping module, yet can be unfolded and locked in the unfolded position to provide a rigid structure for resisting the stress arising from vertical loads and transferring them to lower levels and ultimately the building foundation. These inventions also facilitate defining a basic structural section that can be utilized to construct foldable, transportable buildings of varying size, and simplify their manufacturing.

In one aspect, the present inventions are directed to a hinge assembly rotatable between an open first position and a closed second position comprising (a) a first hinge portion and a second hinge portion, where each such hinge portion comprises (i) a base plate with an obverse face, a reverse face, an upper edge, an opposed lower edge and a base plate vertical centerline; (ii) a hinge section with a hinge section vertical centerline, the hinge section extending from the obverse face and comprising a plurality of spaced-apart hinge leaves symmetrically positioned about the hinge section vertical centerline, with the hinge section vertical centerline being offset from the base plate vertical centerline, each of the plurality of hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures positioned in horizontal alignment with each other along a hinge aperture centerline; (iii) a locking pin barrel extending from the obverse face and positioned to a first side of the base plate vertical centerline, the locking pin barrel defining a bore; (iv) a plurality of locking pin leaves extending from the obverse face and positioned to the first side of the base plate vertical centerline, each locking pin leaf defining a locking pin aperture, the locking pin apertures positioned in vertical alignment with each other, and with the bore of the locking pin barrel; and (v) a plurality of free interlock leaves extending from the obverse face, each free interlock leaf defining an interlock aperture, with the interlock apertures in vertical alignment with each other, and the free interlock leaves positioned to a second side of the base plate vertical centerline at a position so that, when the hinge assembly is in the second position, the free interlock leaves of each of the first and second hinge portions interleave with the locking pin leaves of the other of the first and second hinge portions. The hinge leaves of the first hinge portion are interleaved with the hinge leaves of the second hinge portion, with a hinge pin positioned in the hinge leaf apertures of the interleaved hinge leaves of the first and second hinge portions to pivotally join the first hinge portion and the second hinge portion and permit the second hinge portion to rotate relative to the first hinge portion from the first position to the second position. There is also provided a first locking pin adapted to be inserted into the bore defined in the locking pin barrel of the first hinge portion and received in (i) the locking pin apertures of the first hinge portion and (ii) the interlock apertures of the second hinge portion, when the hinge assembly is in the second position.

In another aspect, the present inventions are directed to a foldable enclosure component having a folded position and an unfolded position comprising (a) a planar first component portion having a planar laminate construction and a first edge; and (b) a planar second component portion having a planar laminate construction and a second edge, with the first edge of the first component portion positioned proximate to the second edge of the second component portion. The planar laminate construction of each of the first and second component portions comprises: (i) a planar foam panel layer having a first face and an opposed second face, (ii) a planar first metal layer having a first face and an opposed second face bonded to the first face of the planar foam panel layer, (iii) a planar second metal layer having a first face bonded to the second face of the planar foam panel layer and an opposed second face; and (iv) a protective layer having an inorganic composition, a first face bonded to the second face of the second metal layer, and an opposed second face. A first hinge assembly joins the planar first component portion and the planar second component portion along their respective first and second edges and is adapted to permit the foldable enclosure component to rotate the second component portion relative to the first component portion from a folded position to an unfolded position, with the protective layers of the first and second component portions positioned adjacent to each other when the second component portion is in the unfolded position.

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 the metal sheets206of first structural layer210using a suitable adhesive, preferably a polyurethane based construction adhesive. Foam panel layer213can include exterior edge reinforcement and interior edge reinforcement, as described further below

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, which 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 at paragraphs 0034-57 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 the foam panel material of foam panel layer213that 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 the foam panel material of foam panel layer213which 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 beam assemblies for floor component300and roof component400are described below.

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 the present application, are incorporated by reference as if fully set forth herein, particularly including the sealing systems described for example at paragraphs 0080-0167 and depicted in FIGS. 9-20 thereof, and also including the exemplary placements for such sealing systems described in paragraphs 0168-0174 and depicted inFIGS. 8A-8Bthereof.

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

Wall Component (200)

Typically, a 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 edges192-1,192-2,194-3and194-4, is 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 third wall portion200s-3by 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 above, 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 such 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 portion300bby means of hinge structures to 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 referenced 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 such hinge structures. Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material.

Floor Component (300)

Typically, a 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 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 layer205being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Above sheet metal layer205there are provided foam panels214of foam panel layer213. In the embodiment shown inFIGS. 4 and 5, foam panels214are EPS foam 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 of the foam panel layer213. 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 shown inFIGS. 1 through 6, the interior edge reinforcement provided by reinforcing boards307is laminated strand lumber board 7.125″ deep and 1.5″ thick.

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 a fully unfolded position, shown inFIGS. 2 and 4, where floor portion300bis horizontally oriented and co-planar with floor portion300a. Particular embodiments of suitable hinge structures for joining floor portion300ato floor portion300bare described below.

C. Hinged Vertical Load Transfer Components

FIG. 8Ashows a beam assembly325that can be placed within floor component300to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne by floor component300to its edges. Beam assembly325includes two I-beams326aand326b. I-beam326ais positioned approximately in the middle of floor portion300a, I-beam326bis positioned approximately in the middle of floor portion300b, and each of I-beams326aand326bis oriented in the transverse direction. A hinge assembly329A joins I-beam326ato I-beam326b. The hinge assembly329A permits beam assembly325to be folded to a beam folded position shown inFIG. 8Band unfolded to a beam unfolded position shown inFIG. 8A. Further, the hinge assembly329A can be locked when beam assembly325is in the beam unfolded position, which transforms beam assembly325into a rigid structure that will reinforce floor component300in the direction perpendicular to its axis of folding.

Hinge Assembly329A. Hinge assembly329A comprises two identical hinge assembly portions330A partnered together to form a pivoted junction. The inter-positioning of the parts of two partnered hinge assembly portions330A is described below, and can also be seen inFIGS. 13D and 13E, which depict the two partnered hinge assembly portions330of a hinge assembly329A that joins floor portion300aand floor portion300b.FIGS. 13D and 13Eare section views, sectioned in the transverse and longitudinal directions respectively.

Hinge assembly portion330A, shown inFIG. 9, in principal part includes a hinge base plate331having a generally planar, rectangular or, as shown inFIGS. 9, 10 and 12, a square configuration, with an obverse face318and a reverse face319(visible inFIG. 12). A hinge section332, a pin interlock section334, a free interlock section338and a locking pin barrel340are secured to the obverse face318of hinge base plate331. Hinge assembly portion330A can be manufactured from steel that is cast as a single piece that includes sections332,334and338, and barrel340.

Hinge section332shown inFIG. 9has four hinge leaves333, each of which extends away in a perpendicular direction from hinge base plate331and defines a hinge pin hole327in the region distal from hinge base plate331. The centerline of each hinge pin hole327is horizontally oriented and aligned with the centerline of the hinge pin holes327in the other three hinge leaves333of hinge section332. Hinge leaves333each has the same thickness and are spaced apart a distance equal to the thickness of a hinge leaf333, so as to permit interleaving the corresponding hinge leaves333of a partnering hinge assembly portion330A.

Pin interlock section334shown inFIG. 9has two pin interlock leaves336. Each pin interlock leaf336extends away in a perpendicular direction from hinge base plate331and defines a lock pin hole347in the region distal from base plate331. The centerline of each lock pin hole347is vertically oriented and in alignment with the centerline of the lock pin hole347of the adjacent pin interlock leaf336. The two pin interlock leaves336each has the same thickness as the other, and are spaced apart a distance equal to the thickness of a pin interlock leaf336.

Free interlock section338shown inFIG. 9has two free interlock leaves339. Each free interlock leaf339extends away in a perpendicular direction from hinge base plate331and defines a lock pin hole347in the region distal from base plate331. The centerline of each lock pin hole347is vertically oriented and in alignment with the lock pin hole347of the adjacent free interlock leaf339. The two free interlock leaves336each has the same thickness as the other, and both free interlock leaves339have the same thickness as pin interlock leaves336. The free interlock leaves339are spaced apart a distance equal to the thickness of a free interlock leaf339(which is equal to the thickness of a pin interlock leaf336).

Locking pin barrel340shown inFIG. 9extends away in a perpendicular direction from hinge base plate331and defines a locking pin bore341. The centerline of bore341is vertically oriented and co-linear with the centerline of lock pin holes347of pin interlock leaves336.

As can be seen inFIG. 10, the vertical centerline343of hinge section332is not coincident with the vertical centerline342of hinge base plate331. Rather, it is offset, in the view shown inFIG. 10, leftward an offset distance344, which is one-half the thickness of a hinge leaf333. This permits utilizing two hinge assembly portions330A with identical designs in a partnering relationship to form the hinge assembly329A and the desired pivoting junction. Hinge assembly329A is assembled by interleaving the hinge leaves333of two hinge assembly portions330A and inserting a hinge pin364through their hinge pin holes327, which can be secured in place using for example an external retaining ring clip. Hinge assembly329A can pivot 90° from a first, hinge open position, where I-beam325is in the beam folded position shown inFIG. 8B, to a second, hinge closed position, where I-beam325is in the beam unfolded position shown inFIG. 8A.

As shown inFIG. 10, the free interlock leaves339of free interlock section338are offset in the vertical direction from the position of the pin interlock leaves336of the pin interlock section334by an offset distance346, which is equal to the thickness of a free interlock leaf339(which is equal to the thickness of a pin interlock leaf336). In the hinge closed position (the beam unfolded position), the free interlock leaves339of the free interlock section338of a first of the two hinge assembly portions330A will interleave with the pin interlock leaves336of the pin interlock section334of the second of the two hinge assembly portions330A, as generally indicated inFIG. 13E. Correspondingly in the hinge closed position (the beam unfolded position), the free interlock leaves339of the free interlock section338of the second of the two hinge assembly portions330A will interleave with the pin interlock leaves336of the pin interlock section334of the first of the two hinge assembly portions330A, again as generally indicated inFIG. 13E. The centerline of lock pin holes347of the free interlock leaves339of each hinge assembly portion330A is positioned so that, when a hinge assembly329A is in the hinge closed position (the beam unfolded position), that lock pin hole centerline will be co-linear with the centerline of the lock pin holes347in the pin interlock section334of the other hinge assembly portion330A of the hinge assembly329A.

As can be appreciated, when hinge assembly329A is in the hinge closed position (the beam unfolded position), there is on each side of the vertical centerline of the assembly a locking pin barrel340positioned over a set of interleaved leaves336,339. The hinge assembly329A is accordingly locked into the hinge closed position by inserting a locking pin349into the locking pin bore341provided in the locking pin barrel340of each of its two hinge assembly portions330A, as shown inFIGS. 13D and 13E.

Locking pin349, which is shown inFIG. 13C, has a length sufficient to be received in the lock pin holes347of the interleaved leaves of336,339positioned below it and thus lock beam assembly325in the beam unfolded position. It is preferable for locking pin349to be cylindrical in cross-section. Also, locking pin349can be tapered along its length, so that the widest cross section is at the upper face of locking pin barrel340. In that case, the diameter of locking pin bore341can be tapered, and the diameters of lock pin holes347in leaves336,339can be correspondingly reduced, the further they are located from locking pin barrel340. Alternatively, and as shown inFIG. 13C, only the portion349aof locking pin349, which is received in lock pin holes347of leaves336,339, can be made tapered (with the diameters of lock pin holes347in leaves336,339being correspondingly reduced, the further they are located from locking pin barrel340), while locking pin bore341, and the portion349bof locking pin349not received in lock pin holes347of leaves336,339, each can be given a uniform diameter. In this latter case, the portion349cof locking pin349(the upper section of portion349b), which is received in locking pin bore341, as well as locking pin bore341itself, can be provided with complimentary screw threads, as shown inFIGS. 13C-13E, to permit securing locking pin349in place.

To facilitate the rotation of hinge assembly329A so that beam assembly325can smoothly move into the beam unfolded position shown inFIG. 8A, it is preferred that the upper and lower faces of leaves336,339not be planar, but rather curved. Referring toFIG. 11, there is shown interlock leaves336in profile. As compared to planar surfaces348, which originate at hinge base plate331and extend out in a direction perpendicular to the plane of hinge base plate331, the upper and lower faces of free interlock leaves339can be seen to be curved, about a point proximate to hinge pin hole327. Similarly, the upper and lower faces of pin interlock leaves336are comparably curved. The curvature varies depending on the face location, with faces closer to pin hole327being more deeply curved than faces further away.

A stop324is optionally provided at the edge of the lower free interlock leaf339of each hinge portion330A of hinge assembly329A to assist in preventing hyper-extending beam assembly325when unfolded. In the case where hinge assembly329A is fabricated as a single casting, stops324of the partnered hinge portions330A of each hinge assembly329A can be more precisely machined or ground down as necessary following the casting step to insure that when hinge assembly329A is in the hinge closed position, I-beams326aand326B do not extend beyond the desired beam unfolded position. In the beam unfolded position (when hinge assembly329A is in the hinge closed position), while I-beams326aand326bcan be co-linear, it is preferred that I-beams326aand326bnot be co-linear. In particular, in the beam unfolded position it is preferred that hinge assembly329A, when joined to I-beams326aand326b, causes those I-beams to assume a small upwardly arched configuration. This can be realized for example by designing hinge assembly portion330A so that when hinge assembly portion330A is secured to an end of an I-beam326aor326b, obverse face318is canted a select positive angle (i.e., angularly rotated clockwise about the centerline of hinge pin holes327shown inFIG. 11), such as one-half degree (+0.5°), relative to the reverse face319of hinge assembly portion330A. This upward arching is intended to reduce or eliminate any sag in floor component300when in the fully unfolded position.

The reverse face319of hinge assembly portion330A is adapted to be secured to an end of one of I-beams326aand326b. The hinge assembly portions330A that join I-beam326aand I-beam326bare secured to I-beams326a,326bwith their hinge sections332oriented upwardly, so that I-beam326bshown inFIG. 8Acan fold up relative to I-beam326a, as shown inFIG. 8B. In particular, as shown inFIG. 12reverse face319is provided with four positioning tabs321, extending away from reverse face319in a perpendicular direction. Each positioning tab321has two flat sections317oriented perpendicular to each other and joined by a rounded section315. The positioning tabs321form a guide frame, having an “I” shape in profile, for receiving an end of one of I-beams326aand326b. It is preferred that the I-beams326a,326bbe secured to the reverse faces319by welding their internal flanges to hinge assembly portions330a. For this purpose, each of the positioning tabs321is preferably provided with a serpentine cut-out322, to increase the length of the weld line with the goal of increasing the strength of the weld.

FIG. 13A, a cutaway view of a portion of floor component300in the floor component unfolded position, depicts the mounting of hinge assembly329A within the floor component300, specifically where floor portion300aabuts floor portion300b. As seen inFIG. 13A(and also visible inFIG. 13E), a bolt plate314joins the reinforcing board307positioned in floor portion300b, adjacent interior edge301b, to the hinge assembly portion330A secured to I-beam326b. A similar bolt plate314is located on the portion of I-beam326bnot visible inFIG. 13A, and similar bolt plates314are located on each side of the partnering hinge assembly portion330A secured to I-beam326a(not visible).

In the embodiment of floor component300shown in the figures, I-beam assembly325is located at the mid-point between first transverse floor edge120and second transverse floor edge118, and no hinge assemblies329A are utilized elsewhere within floor component300, such as proximate to first transverse floor edge120and second transverse floor edge118. Therefore, to assist in smoothly rotating floor portion300b, there is provided adjacent first transverse floor edge120a first floor end hinge assembly345A joining floor portions300aand300b, and there is provided adjacent second transverse floor edge118a second floor end hinge assembly345A joining floor portions300aand300b. The locations of both first and second floor end hinge assemblies345A is indicated inFIG. 13B.

Floor end hinge assembly345A. Floor end hinge assembly345A comprises two identical floor end hinge portions350A. Referring toFIGS. 14A and 14B, floor end hinge portion350in principal part includes a hinge base plate351on which is secured a hinge section352. Hinge section352has five hinge leaves353in the depicted embodiment, each of which extends away in a perpendicular direction from hinge base plate351and defines a hinge pin hole354in the region distal from hinge base plate353. The centerline of each hinge pin hole354is horizontally oriented and aligned with the centerline of the hinge pin holes354in the other hinge leaves353of hinge section352. Hinge leaves353each has the same thickness and are spaced apart a distance equal to the thickness of a hinge leaf353, so as to permit interleaving the corresponding hinge leaves353of the partnering hinge assembly portion350A.

As can be seen inFIG. 14B, the vertical centerline358of hinge section352is not coincident with the vertical centerline359of hinge base plate351. Rather, it is offset, in the view shown inFIG. 14B, rightward an offset distance357, which is one-half the thickness of a hinge leaf353. This permits utilizing two hinge assembly portions350A with identical designs in a partnering relationship to form the hinge assembly345A and the desired pivoting junction. Floor end hinge assembly345A can pivot ninety degrees (90°) from a first, hinge open position, corresponding to where I-beam325is in the folded position shown inFIG. 8B, to a second, hinge closed position, corresponding to where I-beam325is in the unfolded position shown inFIG. 8A. Floor end hinge assembly345A is assembled by interleaving the hinge leaves353of two hinge assembly portions350A and inserting a hinge pin (not visible) through the hinge pin holes354of the interleaved hinge leaves353, which can be secured in place using for example an external retaining ring clip.

Floor end hinge portion350additionally includes two opposed block-out shields355aand355b. Block out shield355ais positioned adjacent a first vertical edge of base plate351and extends away from base plate351in a perpendicular direction. Block out shield355bis positioned proximate to an opposing second vertical edge of base plate351, but is inset an inset distance356equal to at least the thickness of block out shield355a, and extends away from base plate351in a perpendicular direction.

Referring to the floor end hinge assembly345A shown inFIG. 13Badjacent first floor transverse edge120, one of its hinge assembly portions350A is joined to the reinforcing board307adjacent edge301b, and the other of its hinge assembly portions350A is joined to the reinforcing board307adjacent interior edge301a. As to the floor end hinge assembly345A shown inFIG. 13B, which is adjacent second transverse floor edge118, likewise one of its hinge assembly portions350A is joined to the reinforcing board307adjacent edge301a, and the other of its hinge assembly portions350A is joined to the reinforcing board307adjacent second interior edge301b.

Optionally, an I-beam cover505, shown inFIGS. 28A-28Ccan be positioned over the interior flanges (the flanges proximate to the enclosed space of structure150) of each of I-beams326aand326b. I-beam cover505is an elongate member that defines a deep channel506in cross-section dimensioned to be placed over and snugly fit one side of an I-beam flange. As shown inFIG. 28C, two I-beam covers505are positioned abutting each other in an opposed manner to cover both sides of an I-beam flange. I-beam flange cover505is fabricated from a material that, relative to steel, has a low thermal conductivity, such as polyvinyl chloride.

Roof Component (400)

Typically, a 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 finished 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. 1 through 6, the interior edge reinforcement provided by reinforcing boards437of roof component400is laminated strand lumber board 7.125″ deep and 1.5″ thick.

Referring to structure150shown inFIG. 4, roof portion400ais fixed in position relative to first wall portion200s-1, third wall portion200s-3and wall component200R. Roof 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 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 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 suitable hinge structures for joining roof portion400ato roof portion400b, and for joining roof portion400bto roof portion400c, are described below.

C. Hinged Vertical Load Transfer Components

FIGS. 15A and 15Bshows a beam assembly425that can be placed within roof component400to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne by floor component300to its edges. Beam assembly425includes three I-beams426a,426band426c. I-beam426ais positioned approximately in the middle of roof portion400a, I-beam426bis positioned approximately in the middle of floor portion400b, I-beam426cis positioned approximately in the middle of floor portion400c, and each of I-beams426a,426band426cis oriented in the transverse direction. A hinge assembly429B joins I-beam426ato I-beam426b. In addition, a hinge assembly429C joins I-beam426bto I-beam426c. The hinge assemblies429B and429C permit beam assembly425to be folded to a beam folded position, shown inFIG. 15B, and unfolded to a beam unfolded position, shown inFIG. 15A. Further, the hinge assemblies429B and429C can be locked when beam assembly425is in the beam unfolded position, which transforms beam assembly425into a rigid structure that will reinforce roof component400in the direction perpendicular to its axes of folding.

Hinge Assembly429B. Hinge assembly429B comprises two identical hinge assembly portions430B partnered together to form a pivoted junction. The inter-positioning of the parts of the two partnered hinge assembly portions430B forming hinge assembly429B is substantively the same as illustrated inFIGS. 13D and 13Ein reference to the two hinge assembly portions330A forming hinge assembly329A.

Hinge assembly portion430B is shown inFIG. 16. The design of hinge assembly portion430B is similar to hinge assembly portion330A discussed above. Accordingly, referring toFIG. 16, hinge assembly portion430B includes a hinge base plate431having an obverse face418and a reverse face419(visible inFIG. 19). A hinge section432, a pin interlock section434, a free interlock section438and a locking pin barrel440are secured to the obverse face418of hinge plate431. Hinge assembly portion430B can be manufactured from steel that is cast as a single piece that includes sections432,434and438, and barrel440.

Hinge section432shown inFIG. 16has four hinge leaves433. Each hinge leaf433extends away in a perpendicular direction from hinge base plate431and defines a hinge pin hole427in the region distal from hinge base plate431. The centerline of each hinge pin hole427is horizontally oriented and aligned with the centerline of the hinge pin holes427in the other hinge leaves433of hinge section432. Hinge leaves433each has the same thickness and are spaced apart a distance equal to the thickness of a hinge leaf433, so as to permit interleaving the corresponding hinge leaves433of the partnering hinge assembly portion430B.

Pin interlock section434shown inFIG. 16has two pin interlock leaves436. Each pin interlock leaf436extends away in a perpendicular direction from hinge base plate431and defines a lock pin hole447in the region distal from base plate431. The centerline of each lock pin hole447is vertically oriented and in alignment with the centerline of the lock pin hole447of the adjacent pin interlock leaf436. The two pin interlock leaves436each has the same thickness as the other, and are spaced apart a distance equal to the thickness of a pin interlock leaf436.

Free interlock section438shown inFIG. 16has two free interlock leaves439. Each free interlock leaf439extends away in a perpendicular direction from hinge base plate431and defines a lock pin hole447in the region distal from base plate431. The centerline of each lock pin hole447is vertically oriented and co-linear with the centerline of with the lock pin hole447of the adjacent free interlock leaf439. The two free interlock leaves436each has the same thickness as the other, and both free interlock leaves439have the same thickness as pin interlock leaves436. The free interlock leaves439are spaced apart a distance equal to the thickness of a free interlock leaf439(which is equal to the thickness of a pin interlock leaf436).

Locking pin barrel440shown inFIG. 16extends away in a perpendicular direction from base plate431defines a locking pin bore441. The centerline of bore441is vertically oriented and co-linear with the centerline of lock pin holes447of pin interlock leaves436.

As can be seen inFIG. 17, the vertical centerline443of hinge section432is not coincident with the vertical centerline442of hinge base plate431. Rather, it is offset, in the view shown inFIG. 17, leftward an offset distance444, which is one-half the thickness of a hinge leaf433. This permits utilizing two hinge assembly portions430B with identical designs in a partnering relationship to form the hinge assembly429B and the desired pivoting junction. Hinge assembly429B is assembled by interleaving the hinge leaves433of two hinge assembly portions430B and inserting a hinge pin464(shown inFIG. 24A) through their hinge pin holes427, which can be secured in place using for example an external retaining ring clip. Hinge leaves433, visible in profile inFIG. 18, extend above hinge base plate431so that hinge pin holes427are positioned a vertical distance411, the B hinge pin pivot distance, from the lower edge of hinge assembly portion430B. B hinge pin pivot distance411is sufficient to permit hinge assembly429B to pivot one hundred and eighty degrees (180°) from a first, hinge open position, where I-beam425is in the beam folded position shown inFIG. 15B, to a second, hinge closed position, where I-beam425is in the beam unfolded position shown inFIG. 15A.

As shown inFIG. 17, the free interlock leaves439of free interlock section438are offset in the vertical direction from the position of the pin interlock leaves436of the pin interlock section434by an offset distance446, which is equal to the thickness of a free interlock leaf439(which is equal to the thickness of a pin interlock leaf436). In the hinge closed position (the beam unfolded position), the free interlock leaves439of the free interlock section438of a first of the two hinge assembly portions430B will interleave with the pin interlock leaves436of the pin interlock section434of the second of the two hinge assembly portions430B. Correspondingly in the hinge closed position (the beam unfolded position), the free interlock leaves439of the free interlock section438of the second of the two hinge assembly portions430B will interleave with the pin interlock leaves436of the pin interlock section434of the first of the two hinge assembly portions430B. The centerline of lock pin holes447of the free interlock leaves439of each hinge assembly portion430B is positioned so that, when a hinge assembly429B is in the hinge closed position (the beam unfolded position), that lock pin hole centerline will be co-linear with the centerline of the lock pin holes447in the pin interlock section434of the other hinge assembly portion430B of the hinge assembly429B.

As can be appreciated, when hinge assembly429B is in the hinge closed position (the beam unfolded position), there is on each side of the vertical centerline of the assembly a locking pin barrel440positioned over a set of interleaved leaves436,439. The hinge assembly429is accordingly locked into the hinge closed position by inserting a locking pin349(the same as used to lock partnered hinge assembly portions330A in the hinge closed position, and as shown inFIG. 13C) into the locking pin bore441provided in the locking pin barrel440of each of its two hinge assembly portions430B.

Locking pin349has a length sufficient to be received in the lock pin holes447of the interleaved leaves of436,439positioned below it and thus lock beam assembly425in the beam unfolded position. As described above, it is preferable for locking pin349to be cylindrical in cross-section. Also as described above, locking pin349can be tapered along its length, so that the widest cross section is at the upper face of locking pin barrel440. In that case, the diameter of locking pin bore441can be tapered, and the diameters of lock pin holes447in leaves436,439can be correspondingly reduced, the further they are located from locking pin barrel440. Alternatively, and as shown inFIG. 13C, only the portion349aof locking pin349, which is received in lock pin holes447of leaves436,439, can be made tapered (with the diameters of lock pin holes447in leaves436,439being correspondingly reduced, the further they are located from locking pin barrel440), while locking pin bore441, and the portion349bof locking pin349not received in lock pin holes447of leaves436,439, each can be given a uniform diameter. In this latter case, the portion349cof locking pin349(the upper section of portion349b), which is received in locking pin bore441, as well as locking pin bore441itself, can be provided with complimentary screw threads (in the manner depicted inFIGS. 13C-13E), to permit securing locking pin349in place.

To facilitate the rotation of hinge assembly429B so that beam assembly425can smoothly move into the fully unfolded position shown inFIG. 15A, it is preferred that the upper and lower faces of leaves436,439not be planar, but rather curved. Referring toFIG. 18, there is shown interlock leaves436in profile. As compared to planar surfaces448, which originate at hinge base plate431and extend out in an orientation normal to the plane of hinge base plate431, the upper and lower faces of free interlock leaves439can be seen to be curved, about a point proximate to hinge pin hole427. Similarly, the upper and lower faces of pin interlock leaf436immediately below it are comparably curved. The curvature varies depending on the face location, with faces closer to pin hole427being more deeply curved than faces further away.

A stop424is optionally provided at the edge of the lower free interlock leaf439of each hinge portion430B of hinge assembly429B to assist in preventing hyper-extending beam assembly425when unfolded. In the case where hinge assembly429B is fabricated as a single casting, stops424of the partnered hinge portions430B of each hinge assembly429B can be more precisely machined or ground down as necessary following the casting step to insure that when hinge assembly429B is in the hinge closed position, I-beams426aand426bdo not extend beyond the desired beam unfolded position. In the beam unfolded position (when hinge assembly429B is in the hinge closed position), while I-beams426aand426bcan be co-linear, it is preferred that I-beams426aand426bnot be co-linear. In particular, in the beam unfolded position it is preferred that hinge assembly429B, when joined to I-beams426aand426b, causes those I-beams to assume a small upwardly arched configuration. This configuration can be realized for example by designing hinge assembly portion430B so that when hinge assembly portion430B is secured to an end of an I-beam426aor426b, obverse face418is canted a select positive angle (i.e., angularly rotated clockwise about hinge pin hole427inFIG. 18), such as one-half degree (+0.5°), relative to the reverse face419of hinge assembly portion430B. This upward arching is intended to reduce or eliminate any sag in floor component400when in the fully unfolded position.

The reverse face419of hinge assembly portion430B is adapted to be secured to an end of one of I-beams426aand426b. The hinge assembly portions430B that join I-beam426aand I-beam426bare secured to I-beams426a,426bwith their hinge sections432oriented upwardly, so that I-beam426bshown inFIG. 15Acan fold up relative to I-beam426ato the beam folded position shown inFIG. 15B. In particular, as shown inFIG. 19reverse face419is provided with four positioning tabs421extending away from reverse face419in a perpendicular direction. Each positioning tab421has two flat sections417oriented perpendicular to each other and joined by a rounded section415. The positioning tabs421secured to reverse face419form a guide frame, having an “I” shape in profile, for receiving an end of one of I-beams426aand426b. It is preferred that the I-beams426a,426bbe secured to the reverse faces419by welding their flanges to hinge assembly portions430a. For this purpose, each of the positioning tabs421is preferably provided with a serpentine cut-out422, to increase the length of the weld line with the goal of increasing the strength of the weld.

Hinge Assembly429C. Hinge assembly429C comprises two identical hinge assembly portions430C partnered together to form a pivoted junction. The inter-positioning of the parts of the two partnered hinge assembly portions430C forming hinge assembly429C is substantively the same as illustrated inFIGS. 13D and 13Ein reference to the two hinge assembly portions330A forming hinge assembly329A.

Hinge assembly portion430C is shown inFIGS. 20-23. The design of hinge assembly portion430C is the same as hinge assembly portion430B, discussed above, with three exceptions.

The first exception is that the lower pin interlock leaf436of the hinge assembly portion430C is extended toward free interlock section438to provide a platform tab407, which is shown inFIGS. 20 and 21. When hinge assembly429C is in its fully open position in a structure150, the two platform tabs407of the partnered hinge assembly portions430C forming hinge assembly429C provide a foot-supporting area for construction personnel, while protecting the hinge structure.

The second exception is shown inFIG. 22, in which hinge leaves453extend above hinge base plate431so that hinge pin holes427are positioned a vertical distance409, the C hinge pin pivot distance, from the lower edge of hinge assembly portion430C. The C hinge pin pivot distance409is sufficient to permit hinge assembly429C to pivot one hundred and eighty degrees (180°) from a first, open position, where I-beam425is in the beam folded position shown inFIG. 15B, to a second, closed position, where I-beam425is in the beam unfolded position shown inFIG. 15A, without crimping or interfering with such protective layer218(shown inFIG. 22) as may be positioned on second structural layer215.

The third exception relates to the fact that hinge assemblies429B and429C are mounted in opposite orientations. Referring to hinge assembly429B, the reverse face419of each of its two hinge assembly portions430B is adapted to be secured to a respective end of the two I-beams426aand426badjacent to each other, and referring to hinge assembly429C the reverse face419of each of the two hinge assembly portions430C is adapted to be secured to a respective end of the two I-beams426band426cadjacent to each other. As was discussed above, the hinge assembly portions430B that join I-beam426aand I-beam426bare secured to those I-beams426a,426bwith their hinge sections332oriented upwardly, so that I-beam426bshown inFIG. 15Acan fold up relative to I-beam426a. In contrast, hinge assembly portions430C that join I-beam326band I-beam326care secured to I-beams426b,426cwith their hinge sections332oppositely oriented; i.e., oriented downwardly, so that I-beam426cshown inFIG. 15Acan fold down relative to I-beam426b. These orientations permit I-beam425to be folded in an accordion pattern, as shown inFIG. 15B. With these orientations, the three roof components400a,400band400ccan be accordion folded (stacked), as shown inFIG. 3, with roof component400bstacked on top of roof component400a, and roof component400cstacked on top of the roof component400b.

Similar to the beam unfolded position of I-beams426aand426b, while I-beams426band426ccan be co-linear in their beam unfolded position (when hinge assembly429C is in the hinge closed position), it is preferred that I-beams426band426cnot be co-linear in that beam unfolded position. In particular, in the beam unfolded position it is preferred that hinge assembly429C, when joined to I-beams426band426c, causes those I-beams to assume a small upwardly arched configuration. This can be realized for example by designing hinge assembly portion430C so that when hinge assembly portion430C is secured to an end of an I-beam426bor426c, obverse face418is canted in the opposite direction as preferably found in hinge assembly430B; in other words, it is preferred that obverse face418of hinge assembly portion430C be canted a select negative angle (i.e., angularly rotated counterclockwise about hinge pin hole427inFIG. 22), such as minus one-half degree (−0.5°), relative to the reverse face419of hinge assembly portion430C. As stated previously, this upward arching is intended to reduce or eliminate any sag in floor component400when in the fully unfolded position.

FIG. 24A, a cutaway view of a section of roof component400in the roof component unfolded position, depicts the mounting of hinge assembly429B within the floor component400, specifically between floor portion400aand floor portion400b. Bolt plate414joins the reinforcing board437positioned in roof portion400badjacent second interior edge412bto the hinge assembly portion430B secured to I-beam426b. A similar bolt plate414is located on the portion of I-beam426bnot visible inFIG. 24A, and similar bolt plates414are located on each side of the partnering hinge assembly portion430B secured to I-beam426a. Hinge assembly429C is mounted within floor component400at the junction of roof portions400band400cin a similar manner.

In the embodiment of roof component400shown in the figures, I-beam assembly425is located at the mid-point between first transverse roof edge408and second transverse roof edge410, and no hinge assemblies429B or429C are utilized elsewhere within roof component400, such as proximate to first transverse roof edge408or second transverse roof edge410. Therefore, to assist in smoothly rotating roof portion400brelative to roof portion400a, there is provided adjacent first transverse roof edge408a first roof end hinge assembly445B joining roof portions400aand400b, and there is provided adjacent second transverse roof edge410a second roof end hinge assembly445B joining roof portions400aand400b. Additionally, to assist in smoothly rotating roof portion400crelative to roof portion400b, there is provided adjacent first transverse roof edge408a first roof end hinge assembly445C joining roof portions400band400c, and there is provided adjacent second transverse roof edge410a second roof end hinge assembly445C joining roof portions400band400c. The locations of first and second roof end hinge assemblies445B are indicated inFIG. 24B, and the locations of first and second roof end hinge assemblies445C are indicated inFIG. 24B. The designs of roof end hinge assemblies445B and445C are described below.

Roof End Hinge assembly445B. Roof end hinge assembly445B comprises two identical roof end hinge portions450B. Referring toFIG. 25A, roof end hinge portion450B in principal part includes a hinge base plate451on which is secured a hinge section452. Hinge section452has five hinge leaves453in the depicted embodiment, each of which extends in a perpendicular direction away from hinge base plate451and defines a hinge pin hole454in the region distal from hinge base plate453. The centerline of each hinge pin hole454is horizontally oriented and aligned with the centerline of the hinge pin holes454in the other hinge leaves453of hinge section452. Hinge leaves453each has the same thickness and are spaced apart a distance equal to the thickness of a hinge leaf453, so as to permit interleaving the corresponding hinge leaves453of the partnering hinge assembly portion450B.

As depicted inFIG. 25B, the vertical centerline458of hinge section452of roof end hinge portion445B is not coincident with the vertical centerline459of hinge base plate451. Rather, it is offset an offset distance457, which is one-half the thickness of a hinge leaf453. This permits utilizing two hinge assembly portions450B with identical designs in a partnering relationship to form the hinge assembly445B and the desired pivoting junction. Roof end hinge assembly445B is assembled by interleaving the hinge leaves453of two hinge assembly portions450B and inserting a hinge pin (not visible) through their hinge pin holes454, which can be secured in place using for example an external retaining ring clip. As shown inFIG. 25C, hinge leaves453of roof end hinge portion445B extend above hinge base plate451so that hinge pin holes454are positioned a vertical distance461, the B roof end hinge pivot distance, from the lower edge of hinge assembly portion450B. B roof end hinge pivot distance461is sufficient to permit hinge assembly445B to pivot one hundred and eighty degrees (180°) from a first, hinge open position, corresponding to where I-beam425of roof portion400bis in the beam folded position shown inFIG. 15B, to a second, hinge closed position, corresponding to where I-beam425is in the beam unfolded position shown inFIG. 15A.

Roof end hinge portion450B additionally includes two opposed block-out shields455aand455b, which are shown inFIG. 25A. Block out shield455ais positioned adjacent a first vertical edge of base plate451and extends away from base plate451in a perpendicular direction. Like the positioning of block out shield355bof floor end hinge portion351, block out shield455bis positioned proximate to an opposing second vertical edge of base plate451, but inset an inset distance456equal to at least the thickness of block-out shield455a, and extending away from base plate351in a perpendicular direction.

The roof end hinge assemblies445B shown inFIG. 24Bhave their hinge sections452oriented up, so that roof portion400bcan be folded upward relative to roof portion400a. The roof end hinge assembly445B that is adjacent first roof transverse edge408inFIG. 24Bis secured in place by joining one of its hinge assembly portions450B to the reinforcing board437adjacent edge412a, and by joining the other of its hinge assembly portions450B to the reinforcing board437adjacent second interior edge412b. As to the roof end hinge assembly445B shown inFIG. 24B, which is adjacent second roof transverse edge408, likewise one of its hinge assembly portions450B is joined to the reinforcing board437adjacent edge412a, and the other of its hinge assembly portions450B is joined to the reinforcing board437adjacent second interior edge412b.

Roof End Hinge assembly445C. Roof end hinge assembly445C comprises two identical roof end hinge portions450C, one of which is shown inFIG. 25D. The principal elements and geometry of roof end hinge portion450C are the same as roof end hinge portion450B, except that hinge leaves453of roof end hinge portion445C extend above hinge base plate451so that hinge pin holes454are positioned a vertical distance462, the C roof end hinge pivot distance, from the lower edge of hinge assembly portion450C. C roof end hinge pivot distance462is sufficient to permit hinge assembly445C to pivot one hundred and eighty degrees (180°) from a first, hinge open position, corresponding to where I-beam425of roof portion400bis in the beam folded position shown inFIG. 15B, to a second, hinge closed position, corresponding to where I-beam425is in the beam unfolded position shown inFIG. 15A, without crimping or interfering with such protective layer218as may be positioned on second structural layer215. Each roof end hinge assembly445C is completed by inserting a hinge pin (not visible) in the hinge pin holes454of the interleaved hinge leaves453of the partnered hinge assembly portions450C, which can be secured in place using for example an external retaining ring clip.

The roof end hinge assemblies445C shown inFIG. 24Bhave their hinge sections452oriented down, so that roof portion400ccan be folded downward relative to roof portion400b. The roof end hinge assembly445C that is adjacent first roof transverse edge408inFIG. 24Bis secured in place by joining one of its hinge assembly portions450C to the reinforcing board437that is adjacent first interior edge412b, and by joining the other of its hinge assembly portions450C to the reinforcing board437adjacent interior edge412c. As to the roof end hinge assembly445C shown inFIG. 24B, which is adjacent second roof transverse edge408, likewise one of its hinge assembly portions450C is joined to the reinforcing board437that is adjacent first interior edge412b, and by joining the other of its hinge assembly portions450C to the reinforcing board437adjacent interior edge412c.

Optionally, an I-beam cover505, as shown inFIGS. 28A-28Cand described above, can be positioned over the interior flanges (the flanges proximate to the enclosed space of structure150) of each of I-beams426a,426band326c.

Enclosure Component Manufacture

For enclosure components155having the construction 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 at paragraphs 00187-00205 and 00212 and in FIGS. 8, 9A-9C, 23A-23J and 24A-24B thereof.

FIG. 26depicts a facility10for fabricating the enclosure components155. The facility comprises a conveyor table50, a press table51, and in the embodiment shown inFIG. 5, four material turntables52A,52B,52C and52D and four robotic assemblers54A,54B,54C and54D. There is also an adhesive spray gantry55straddling the conveyor table50. Whether partitioned or not, all of the enclosure components155—wall components200, floor components300and roof components400—can be formed on the same facility10.

Conveyor table50is provided with a plurality of cylindrical rollers to facilitate movement of work pieces from the assembly area56into the press table51. The enclosure components155are built up, layer upon layer, in the assembly area56, and then moved into the press table51. Press table51preferably employs a vacuum bag system to press together the layers forming enclosure components155. Spray gantry55is movable over conveyor table50between a first position proximate to press table51and a second position distal from press table51. Spray gantry55is provided with a number of downward-directed spray heads for spraying adhesive, such as polyurethane based construction adhesive, onto the work pieces, as directed.

The facility10depicted inFIG. 26can fabricate up to two complete enclosure components155simultaneously, although it is equally capable of forming subassemblies thereof, such as laminated panel sections used to form complete enclosures components155. Thus robotic assemblers54A and54B are positioned as opposed pairs with conveyor table50between them, as shown inFIG. 26, and are used to move sheets and panels from turntables52A and52B, respectively, to appropriate locations on conveyor table50to form a first enclosure component155, or a first laminated panel section for an enclosure component155. Likewise, robotic assemblers54C and54D are positioned as opposed pairs with conveyor table50between them, as shown inFIG. 26, and are used to move sheets and panels from turntables52C and52D, respectively, to appropriate locations on conveyor table50to form a second enclosure component155, or a second laminated panel section for an enclosure component155.

Additional information concerning the facility10shown inFIG. 26, 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 inventors 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 at paragraphs 00178-00186 and 00206-00222, and in FIGS. 22, 23A-23J and 24A-24B.

Enclosure Component Relationships and Assembly for Transport

It is preferred that there be a specific dimensional relationship among enclosure components155. In reference to the embodiment shown in the figures, it is preferred that the height “H” of wall components200be the same as the span “Sf” between the I-beam assembly325of floor component300and either its first transverse floor edge120or its second transverse floor edge118, with I-beam assembly325being located at the middle of floor component300. Correspondingly, it is preferred that the height of wall components200be the same as the span “Sr” between the I-beam assembly425of roof component400and either its first transverse roof edge408or its second transverse roof edge410, with I-beam assembly425being located at the middle of roof component400. Thus it is preferred that H=Sf=Sr. Accordingly, Sfand Srare referred to herein simply as “S”, the panel section span.

Making H=S improves the production throughput of manufacturing facility10. Specifically, manufacturing facility10can be tasked with making multiple laminate panel sections sharing a common dimension based upon the bed width49of conveyor table50shown inFIG. 26, which can then be used to assemble either floor components300or roof components400. In an embodiment of manufacturing facility10shown inFIG. 26, the bed width49can accommodate work pieces having a dimension up to approximately 9.5 feet. Correspondingly, in the embodiment shown in the figures, the panel section span S between I-beam assembly325and either of the first and second transverse floor edges120,118is 9.5 feet, and the panel section span S between I-beam assembly425either of the first and second transverse roof edges408,410is 9.5 feet. Further, by selecting foam panels214of different thickness, wall components200can also be manufactured utilizing panel sections of span S. Accordingly, each wall component200in the embodiment of structure150shown inFIG. 1has a height H of 9.5 feet.

These same height/span relationships can also be utilized to make structures150where two of its opposing wall components200are longer than the other two opposing wall components200. For example,FIG. 27depicts a roof component400approximately 1.5 times longer in the longitudinal direction than in the transverse direction. In this example, roof portions400a,400band400care each assembled from a series of three laminate panel sections, each such section having a panel section span of 9.5 feet in the longitudinal direction. The laminate panel sections of each of the three roof portions400a,400band400care joined by two beam assemblies425, rather than one as in the embodiment shown inFIG. 1, to yield a roof component400approximately 29 feet long by 19 feet wide. The wall floor component300and wall components200are assembled from similarly-dimensioned laminate panel sections to yield the desired rectangular structure150. The foregoing design relationship can be extended to a structure150of any length in the longitudinal direction simply by adding, in the case of roof component400as an example, one or more additional beam assemblies425and further series of laminate panel sections.

FIG. 2shows a top schematic view of finished 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 structure150, including perimeter boards310, preferably 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 portion400c(which is stacked upon roof portions400aand400bwhen roof portions400b,400care fully folded) can be dimensioned to be larger than either of roof portion400aand roof portion400bin the transverse direction for example, by ten to fifteen percent, or by at least the aggregate thickness of roof components400aand400b. This transverse direction dimensional increase is to reduce the chances of binding during the unfolding of roof portions400b,400c. 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,” and filed on Feb. 10, 2020, 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 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. In such a case, roof portion400ccan be dimensioned larger than either of roof portions400aand400bin the transverse direction by at least the aggregate thickness of roof components400aand400b, less the length of the first or second wheel caster.

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.

The shipping module100shown edge-on inFIG. 3includes a fixed space portion102defined by roof component400a, floor component300a, wall component200R, wall portion200s-1and wall portion200s-3. As shown inFIG. 2, second wall portion200s-2is folded inward and positioned generally against fixed space portion102, and fourth wall portion200s-4is folded inward and positioned generally against second wall portion200s-2(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 accordion 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.

It is preferred that the fixed space portion102be in a relatively finished state prior to positioning (folding) together all of the other wall, roof and floor portions as described above. 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, and fixed space portion102is fitted during manufacture with all mechanical and other functionality that structure150will require, such as kitchens, bathrooms, closets and other interior partitions, storage areas, corridors, etc. 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.

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 module is shipped to the building site by appropriate transport means. One such transport means is disclosed in U.S. Pat. No. 11,007,921, issued May 18, 2021; the contents of which are incorporated by reference as if fully set forth herein, particularly as found at column3, line26to column6, line25and inFIGS. 1A-2Dthereof. 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. 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 at paragraphs 00126-00128 and in connection withFIGS. 11A and 11Bthereof.

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(shown inFIG. 3behind perimeter board312) 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. When accordion folded as a stack, it can be appreciated that the protective layer218of roof portion400ais distal from the protective layer of roof portion400b, whereas the protective layer218of roof portion400bis in contact with, or proximate to, the protective layer of roof portion400c. Thus in unfolding roof portions400band400c, it is regarded herein that the protective layer218of the second component portion rotates toward the protective layer218of the first component portion400a, whereas the protective layer218of the third component portion400crotates away from the protective layer218of the second component portion400b.

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. 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 at paragraphs 00132-00145 and depicted inFIGS. 12A-14Bthereof.

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 hinge assembly rotatable between an open first position and a closed second position comprising:

(a) a first hinge portion and a second hinge portion, each such hinge portion comprising:

(i) a base plate with an obverse face, a reverse face, an upper edge, an opposed lower edge and a base plate vertical centerline;

(ii) a hinge section with a hinge section vertical centerline, the hinge section extending from the obverse face and comprising a plurality of spaced-apart hinge leaves symmetrically positioned about the hinge section vertical centerline, with the hinge section vertical centerline being offset from the base plate vertical centerline, each of the plurality of hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures positioned in horizontal alignment with each other along a hinge aperture centerline;

(iii) a locking pin barrel extending from the obverse face and positioned to a first side of the base plate vertical centerline, the locking pin barrel defining a bore;

(iv) a plurality of locking pin leaves extending from the obverse face and positioned to the first side of the base plate vertical centerline, each locking pin leaf defining a locking pin aperture, the locking pin apertures positioned in vertical alignment with each other, and with the bore of the locking pin barrel; and

(v) a plurality of free interlock leaves extending from the obverse face, each free interlock leaf defining an interlock aperture, with the interlock apertures in vertical alignment with each other, the free interlock leaves positioned to a second side of the base plate vertical centerline at a position so that, when the hinge assembly is in the second position, the free interlock leaves of each of the first and second hinge portions interleave with the locking pin leaves of the other of the first and second hinge portions;

(b) the hinge leaves of the first hinge portion interleaved with the hinge leaves of the second hinge portion, with a hinge pin positioned in the hinge leaf apertures of the interleaved hinge leaves of the first and second hinge portions to pivotally join the first hinge portion and the second hinge portion and permit the second hinge portion to rotate relative to the first hinge portion from the first position to the second position; and

(c) a first locking pin adapted to be inserted into the bore defined in the locking pin barrel of the first hinge portion and received in (i) the locking pin apertures of the first hinge portion and (ii) the interlock apertures of the second hinge portion, when the hinge assembly is in the second position.

Clause 2. The hinge assembly of clause 1, further comprising a second locking pin adapted to be inserted into the bore defined in the locking pin barrel of the second hinge portion and received in (i) the locking pin apertures of the second hinge portion and (ii) the interlock apertures of the first hinge portion, when the hinge assembly is in the second position.

Clause 3. The hinge assembly of either clause 1 or 2, wherein the hinge section vertical centerline of each of the first and second hinge portions is positioned so that the base plate vertical centerline of the first and second hinge portions are in an overlying relationship when the hinge assembly is in the second position.

Clause 4. The hinge assembly of any one of clause 1, 2 or 3, wherein each of the plurality of spaced-apart hinge leaves of each of the first and second hinge portions has a thickness the same as the other of the plurality of spaced-apart hinge leaves, and the hinge leaves are spaced-apart a distance equal to the thickness.

Clause 5. The hinge assembly of clause 4, wherein the hinge section vertical centerline of each of the first and second hinge portions is positioned so that the base plate vertical centerline of the first and second hinge portions is offset from the hinge section vertical centerline an offset distance equal to one-half the thickness of any of the plurality of spaced-apart hinge leaves.

Clause 6. The hinge assembly of any one of clause 1, 2, 3, 4 or 5 wherein at least a portion of the first locking pin is tapered.

Clause 7. The hinge assembly of any one of clause 1, 2, 3, 4, 5 or 6, wherein the first locking pin is cylindrical in cross-section.

Clause 8. The hinge assembly of any one of clause 1, 2, 3, 4, 5, 6 or 7, wherein a portion of the first locking pin, adapted to be received in (i) the locking pin apertures of the first hinge portion and (ii) the interlock apertures of the second hinge portion, when the hinge assembly is in the second position, is tapered.

Clause 9. The hinge assembly of any one of clauses 1-8, wherein the locking pin apertures of each of the first and second hinge portions are smaller with increasing distance from the hinge aperture centerline.

Clause 10. The hinge assembly of any one of clauses 1-9, wherein the interlock apertures of each of the first and second hinge portions are smaller with increasing distance from the hinge aperture centerline.

Clause 11. The hinge assembly of any one of clauses 1-10, wherein each locking pin leaf of each of the first and second hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 12. The hinge assembly of any one of clauses 1-11, wherein each free interlock leaf of each of the first and second hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 13. The hinge assembly of any one of clauses 1-12, wherein of each of the first and second hinge portions further comprises a stop projection extending from a free interlock leaf at a point distal from its base.

Clause 14. The hinge assembly of any one of clauses 1-13, wherein the reverse face of the first hinge portion is adapted to be secured to an end of a first beam by one or more positioning tabs extending away from the reverse face of the first hinge portion, which one or more positioning tabs are positioned to conform to the profile of the end of the first beam, and wherein the reverse face of the second hinge portion is adapted to be secured to an end of a second beam by one or more positioning tabs extending away from the reverse face of the second hinge portion, which one or more positioning tabs are positioned to conform to the profile of the end of the second beam.

Clause 15. The hinge assembly of clause 14, wherein the one or more positioning tabs of the first hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile, and the one or more positioning tabs of the second hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile.

Clause 16. The hinge assembly of clause 15, wherein at least one of the plural positioning tabs of the first hinge assembly is provided with a serpentine cut-out, and at least one of the plural positioning tabs of the second hinge assembly is provided with a serpentine cut-out.

Clause 17. The hinge assembly of any one of clauses 1-16, wherein the hinge leaves extend from the obverse face so that the hinge aperture centerline is positioned above the upper edge.

Clause 18. The hinge assembly of any one of clauses 1-16, wherein the hinge leaves extend from the obverse face proximate the upper edge and a sufficient distance from the lower edge so that the hinge assembly can rotate through one hundred eighty degrees from the first position to the second position.

Clause 19. A folding beam assembly rotatable from a folded position to an unfolded position comprising:

(a) a first beam having a first end;

(b) a second beam having a second end and an opposed third end;

(c) a first hinge portion secured to the first end and a second hinge portion secured to the second end, each such hinge portion comprising:

(i) a base plate with an obverse face, a reverse face, an upper edge, an opposed lower edge and a base plate vertical centerline;

(ii) a hinge section with a hinge section vertical centerline, the hinge section extending from the obverse face and comprising a plurality of spaced-apart hinge leaves symmetrically positioned about the hinge section vertical centerline, with the hinge section vertical centerline being offset from the base plate vertical centerline, each of the plurality of hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures positioned in horizontal alignment with each other along a hinge aperture centerline;

(iii) a locking pin barrel extending from the obverse face and positioned to a first side of the base plate vertical centerline, the locking pin barrel defining a bore;

(iv) a plurality of locking pin leaves extending from the obverse face and positioned to the first side of the base plate vertical centerline, each locking pin leaf defining a locking pin aperture, the locking pin apertures positioned in vertical alignment with each other, and with the bore of the locking pin barrel; and

(v) a plurality of free interlock leaves extending from the obverse face, each free interlock leaf defining an interlock aperture, with the interlock apertures in vertical alignment with each other, the free interlock leaves positioned to a second side of the base plate vertical centerline at a position so that, when the second beam is in an unfolded position relative to the first beam, the free interlock leaves of each of the first and second hinge portions interleave with the locking pin leaves of the other of the first and second hinge portions;

(d) the hinge leaves of the first hinge portion interleaved with the hinge leaves of the second hinge portion, with a hinge pin positioned in the hinge leaf apertures of the interleaved hinge leaves of the first and second hinge portions to pivotally join the first hinge portion and the second hinge portion and permit the second beam to rotate relative to the first beam from the folded position to the unfolded position; and

(e) a first locking pin adapted to be inserted into the bore defined in the locking pin barrel of the first hinge portion and received in (i) the locking pin apertures of the first hinge portion and (ii) the interlock apertures of the second hinge portion, when the second beam is in the unfolded position relative to the first beam.

Clause 20. The folding beam assembly of clause 19, further comprising a second locking pin adapted to be inserted into the bore defined in the locking pin barrel of the second hinge portion and received in (i) the locking pin apertures of the second hinge portion and (ii) the interlock apertures of the first hinge portion, when the second beam is in the unfolded position relative to the first beam.

Clause 21. The folding beam assembly of either clause 19 or 20, wherein the hinge section vertical centerline of each of the first and second hinge portions is positioned so that the base plate vertical centerline of the first and second hinge portions are in an overlying relationship when the hinge assembly is in the unfolded position.

Clause 22. The folding beam assembly of any one of clause 19, 20 or 21, wherein each of the plurality of spaced-apart hinge leaves of each of the first and second hinge portions has a thickness the same as the other of the plurality of spaced-apart hinge leaves, and the hinge leaves are spaced-apart a distance equal to the thickness.

Clause 23. The folding beam assembly of clause 22, wherein the hinge section vertical centerline of each of the first and second hinge portions is positioned so that the base plate vertical centerline of the first and second hinge portions is offset from the hinge section vertical centerline an offset distance equal to one-half the thickness of any of the plurality of spaced-apart hinge leaves.

Clause 24. The folding beam assembly of any one of clause 19, 20, 21, 22 or 23, wherein each locking pin leaf of each of the first and second hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 25. The folding beam assembly of any one of clause 19, 20, 21, 22, 23 or 24, wherein each free interlock leaf of each of the first and second hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 26. The folding beam assembly of any one of clauses 19-25, wherein the first end of the first beam is received in one or more positioning tabs extending away from the reverse face of the first hinge portion, which one or more positioning tabs are positioned to conform to a profile of the first end of the first beam, and wherein the second end of the second beam is received in one or more positioning tabs extending away from the reverse face of the second hinge portion, which one or more positioning tabs are positioned to conform to a profile of the second end of the second beam.

Clause 27. The folding beam assembly of clause 26, wherein the one or more positioning tabs of the first hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile, and the one or more positioning tabs of the second hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile.

Clause 28. The folding beam assembly of clause 27, wherein at least one of the plural positioning tabs of the first hinge assembly is provided with a serpentine cut-out, and at least one of the plural positioning tabs of the second hinge assembly is provided with a serpentine cut-out.

Clause 29. The folding beam assembly of clause 28, wherein the first hinge portion is secured to the first beam by a weld line along at least part of the serpentine cut-out thereof, and the second beam assembly portion is secured to the second beam by a weld line along at least part of the serpentine cut-out thereof.

Clause 30. The folding beam assembly of any one of clauses 19-29, wherein the first beam and the second beam are co-linear when the folding beam assembly is in the unfolded position.

Clause 31. The folding beam assembly of any one of clauses 19-29, wherein the first beam and the second beam are not co-linear when the folding beam assembly is in the unfolded position.

Clause 32. The folding beam assembly of clause 31, wherein the obverse face of each of the first and second hinge portions is canted a positive angle about the hinge aperture centerline relative to the reverse face thereof.

Clause 33. The folding beam assembly of clause 31, wherein the obverse face of each of the first and second hinge portion is not coplanar with the respective reverse face thereof.

Clause 34. The folding beam assembly of any one of clauses 19-33, further comprising:

(f) a third beam having a fourth end;

(g) a third hinge portion secured to the third end and a fourth hinge portion secured to the fourth end, each such hinge portion comprising:

(i) a base plate with an obverse face, a reverse face, an upper edge, an opposed lower edge and a base plate vertical centerline;

(ii) a hinge section with a hinge section vertical centerline, the hinge section extending from the obverse face and comprising a plurality of spaced-apart hinge leaves symmetrically positioned about the hinge section vertical centerline, with the hinge section vertical centerline being offset from the base plate vertical centerline, each of the plurality of hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures positioned in horizontal alignment with each other along a hinge aperture centerline;

(iii) a locking pin barrel extending from the obverse face and positioned to a first side of the base plate vertical centerline, the locking pin barrel defining a bore;

(iv) a plurality of locking pin leaves extending from the obverse face and positioned to the first side of the base plate vertical centerline, each locking pin leaf defining a locking pin aperture, the locking pin apertures positioned in vertical alignment with each other, and with the bore of the locking pin barrel; and

(v) a plurality of free interlock leaves extending from the obverse face, each free interlock leaf defining an interlock aperture, with the interlock apertures in vertical alignment with each other, the free interlock leaves positioned to a second side of the base plate vertical centerline at a position so that, when the third beam is in an unfolded position relative to the second beam, the free interlock leaves of each of the third and fourth hinge portions interleave with the locking pin leaves of the other of the third and fourth hinge portions;

(h) the hinge leaves of the third hinge portion interleaved with the hinge leaves of the fourth hinge portion, with a hinge pin positioned in the hinge leaf apertures of the interleaved hinge leaves of the third and fourth hinge portions to pivotally join the third hinge portion and the fourth hinge portion and permit the third beam to rotate relative to the second beam; and

(i) a third locking pin adapted to be inserted into the bore defined in the locking pin barrel of the third hinge portion and received in (i) the locking pin apertures of the third hinge portion and (ii) the interlock apertures of the fourth hinge portion, when the third beam is in the unfolded position relative to the second beam.

Clause 35. The folding beam assembly of clause 34, further comprising a fourth locking pin adapted to be inserted into the bore defined in the locking pin barrel of the fourth hinge portion and received in (i) the locking pin apertures of the fourth hinge portion and (ii) the interlock apertures of the third hinge portion, when the third beam is in the unfolded position relative to the second beam.

Clause 36. The folding beam assembly of either of clause 34 or 35, wherein the second beam and the third beam are co-linear when the folding beam assembly is in the unfolded position.

Clause 37. The folding beam assembly of either of clause 34 or 35, wherein the second beam and the third beam are not co-linear when the folding beam assembly is in the unfolded position.

Clause 38. The folding beam assembly of any one of clause 34, 35 or 37, wherein the obverse face of each of the third and fourth hinge portions is not coplanar with the respective reverse face thereof.

Clause 39. The folding beam assembly of any one of clauses 34-38, wherein the hinge aperture centerline of each of the first, second, third and fourth hinge portions is closer to the upper edge of the base plate thereof than to the lower edge thereof.

Clause 40. The folding beam assembly of clause 39, wherein the first and second hinge portions are secured to the first and second ends in a first orientation, and the third and fourth hinge portions are secured to the third and fourth ends in a second orientation, where the first orientation is opposite to the second orientation so that the beam assembly folds in an accordion pattern.

Clause 41. The folding beam assembly of any one of clauses 34-40, wherein the hinge aperture centerlines of the first and second hinge portions are positioned a hinge pivot distance from the lower edges of the first and second hinge portions sufficient so that the second component portion can rotate relative to the first component portion at least one hundred eighty degrees from a folded position to an unfolded position.

Clause 42. The folding beam assembly of clause 41, wherein the hinge aperture centerlines of the third and fourth hinge portions are positioned a hinge pivot distance from the lower edges of the third and fourth hinge portions sufficient so that the third component portion can rotate relative to the second component portion at least one hundred eighty degrees from a folded position to an unfolded position.

Clause 43. The folding beam assembly of clause 40, wherein the obverse face of each of the first and second hinge portions is canted a positive angle about the hinge aperture centerline relative to the reverse face thereof.

Clause 44. The folding beam assembly of clause 43, wherein the obverse face of each of the third and fourth hinge portions is canted a negative angle about the hinge aperture centerline relative to the reverse face thereof.

Clause 45. A foldable enclosure component having a folded position and an unfolded position comprising:

(a) a planar first component portion having a planar laminate construction and a first edge, and a first beam reinforcing the planar laminate construction with a first end positioned proximate to the first edge;

(b) a planar second component portion having a planar laminate construction and an elongate second edge, and a second beam reinforcing the planar laminate construction with a second end positioned proximate to the second edge, with the first edge of the first component portion positioned proximate to the second edge of the second component portion;

(c) the planar laminate construction of each of the first and second component portions comprising: (i) a planar foam panel layer having a first face and an opposed second face, (ii) a planar first metal layer bonded to the first face of the planar foam panel layer, and (iii) a planar second metal layer bonded to the second face of the planar foam panel layer; and

(d) a first hinge assembly comprising a first hinge portion and a second hinge portion, the first hinge portion secured to the first end of the first beam and the second hinge portion secured to the second end of the second beam, the first hinge portion pivotally joined to the second hinge portion to permit the second component portion to rotate relative to the first component portion from a folded position to an unfolded position.

Clause 46. The foldable enclosure component of clause 45, wherein each of the first hinge portion and the second hinge portion comprises:

(i) a base plate with an obverse face, a reverse face, an upper edge, an opposed lower edge and a base plate vertical centerline;

(ii) a hinge section with a hinge section vertical centerline, the hinge section extending from the obverse face and comprising a plurality of spaced-apart hinge leaves symmetrically positioned about the hinge section vertical centerline, with the hinge section vertical centerline being offset from the base plate vertical centerline, each of the plurality of hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures positioned in horizontal alignment with each other along a hinge aperture centerline;

(iii) a locking pin barrel extending from the obverse face and positioned to a first side of the base plate vertical centerline, the locking pin barrel defining a bore;

(iv) a plurality of locking pin leaves extending from the obverse face and positioned to the first side of the base plate vertical centerline, each locking pin leaf defining a locking pin aperture, the locking pin apertures positioned in vertical alignment with each other, and with the bore of the locking pin barrel; and

(v) a plurality of free interlock leaves extending from the obverse face, each free interlock leaf defining an interlock aperture, with the interlock apertures in vertical alignment with each other, the free interlock leaves positioned to a second side of the base plate vertical centerline at a position so that, when the second component portion is in the unfolded position relative to the first component portion, the free interlock leaves of each of the first and second hinge portions interleave with the locking pin leaves of the other of the first and second hinge portions, wherein:

(e) the hinge leaves of the first hinge portion interleave with the hinge leaves of the second hinge portion, with a hinge pin positioned in the hinge leaf apertures of the interleaved hinge leaves of the first and second hinge portions to pivotally join the first hinge portion and the second hinge portion and permit the second component portion to rotate relative to the first component portion; and the foldable enclosure component additionally comprises:

(f) a first locking pin adapted to be inserted into the bore defined in the locking pin barrel of the first hinge portion and received in (i) the locking pin apertures of the first hinge portion and (ii) the interlock apertures of the second hinge portion, when the second component portion is in the unfolded position relative to the first component portion.

Clause 47. The foldable enclosure component of clause 46, further comprising a second locking pin adapted to be inserted into the bore defined in the locking pin barrel of the second hinge portion and received in (i) the locking pin apertures of the second hinge portion and (ii) the interlock apertures of the first hinge portion, when the second component portion is in the unfolded position relative to the first component portion.

Clause 48. The foldable enclosure component of either of clause 46 or 47, wherein each of the plurality of spaced-apart hinge leaves of each of the first and second hinge portions has a thickness the same as the other of the plurality of spaced-apart hinge leaves, and the hinge leaves are spaced-apart a distance equal to the thickness.

Clause 49. The foldable enclosure component of clause 48, wherein the hinge section vertical centerline of each of the first and second hinge portions is positioned so that the base plate vertical centerline of the first and second hinge portions is offset from the hinge section vertical centerline an offset distance equal to one-half the thickness of any of the plurality of spaced-apart hinge leaves.

Clause 50. The foldable enclosure component of any one of clause 46, 47, 48 or 49, wherein each locking pin leaf of each of the first and second hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 51. The foldable enclosure component of any one of clause 46, 47, 48, 49 or 50, wherein each free interlock leaf of each of the first and second hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 52. The foldable enclosure component of any one of clauses 46-51, wherein the first end of the first beam is received in one or more positioning tabs extending away from the reverse face of the first hinge portion, which one or more positioning tabs are positioned to conform to a profile of the first end of the first beam, and wherein the second end of the second beam is received in one or more positioning tabs extending away from the reverse face of the second hinge portion, which one or more positioning tabs are positioned to conform to a profile of the second end of the second beam.

Clause 53. The foldable enclosure component of clause 52, wherein each of the first and second beams has an “I” shape in profile, and the one or more positioning tabs of the first hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile, and the one or more positioning tabs of the second hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile.

Clause 54. The foldable enclosure component of clause 53, wherein at least one of the plural positioning tabs of the first hinge portions is provided with a serpentine cut-out, and at least one of the plural positioning tabs of the second hinge portions is provided with a serpentine cut-out.

Clause 55. The foldable enclosure component of clause 54, wherein the first hinge portion is secured to the first beam by a weld line along at least part of the serpentine cut-out thereof, and the second beam assembly portion is secured to the second beam by a weld line along at least part of the serpentine cut-out thereof.

Clause 56. The foldable enclosure component of any one of clauses 45-55, wherein the first beam and the second beam are co-linear when the folding beam assembly is in the unfolded position.

Clause 57. The foldable enclosure component of any one of clauses 45-55, wherein the first beam and the second beam are not co-linear when the folding beam assembly is in the unfolded position.

Clause 58. The foldable enclosure component of clause 46, wherein the obverse face of each of the first and second hinge portions is canted a positive angle about the hinge aperture centerline relative to the reverse face thereof.

Clause 59. The foldable enclosure component of clause 46, wherein the obverse face of each of the first and second hinge portion is not coplanar with the respective reverse face thereof.

Clause 60. The foldable enclosure component of any one of clauses 45-59, wherein the first hinge assembly is adapted to permit the foldable enclosure component to rotate the second component portion relative to the first component portion from a folded position to an unfolded position at least ninety degrees from the folded position.

Clause 61. The foldable enclosure component of any one of clauses 45-60, wherein the first hinge assembly is adapted to permit the foldable enclosure component to rotate the second component portion relative to the first component portion from a folded position to an unfolded position at least one hundred eighty degrees from the folded position.

Clause 62. The foldable enclosure component of any one of clauses 45-61, further comprising:

(g) a second hinge assembly having a third hinge portion and a fourth hinge portion, wherein the third and fourth hinge portions each comprises:

(i) a base plate with an obverse face, a reverse face, a first vertical edge, an opposed second vertical edge and a base plate vertical centerline; and

(ii) a hinge section with a hinge section vertical centerline, the hinge section extending from the obverse face and comprising a plurality of spaced-apart hinge leaves symmetrically positioned about the hinge section vertical centerline, with the hinge section vertical centerline being offset from the base plate vertical centerline, each of the plurality of hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures positioned in horizontal alignment with each other along a hinge aperture centerline;

(h) a hinge pin positioned in the hinge leave apertures of the third hinge portion and the fourth hinge portion to pivotally join the third hinge portion and the fourth hinge portion; and

(i) the third hinge portion secured to the first component portion adjacent the first edge thereof at a location distal from the first hinge assembly, and the fourth hinge portion secured to the second component portion adjacent the second edge thereof at a location distal from the first hinge assembly.

Clause 63. The foldable enclosure component of clause 62, further comprising a planar first shield having a thickness and extending from the obverse face of the third hinge portion adjacent the first vertical edge thereof, and a planar second shield having a thickness and extending from the obverse face of the fourth hinge portion adjacent the first vertical edge thereof.

Clause 64. The foldable enclosure component of clause 63, further comprising a planar third shield extending from the obverse face of the third hinge portion proximate to the second vertical edge thereof inset an inset distance at equal to or greater than the thickness of the second shield, and a planar fourth shield extending from the obverse face of the fourth hinge portion proximate to the second vertical edge thereof inset an inset distance equal to or greater than the thickness of the first shield.

Clause 65. The foldable enclosure component of clause 53, wherein the first beam comprises a pair of elongate opposed flanges, and the foldable enclosure component further comprises a pair of elongate insulating members, each of the pair of insulating members defining a channel in which is positioned a respective one of the pair of opposed flanges.

Clause 66. The foldable enclosure component of clause 65, wherein each of the pair of elongate insulating members is polyvinyl chloride.

Clause 67. A foldable enclosure component having a folded position and an unfolded position comprising:

(a) a planar first component portion having a planar laminate construction and a first edge;

(b) a planar second component portion having a planar laminate construction, a second edge and an opposed third edge, with the first edge of the first component portion positioned proximate to the second edge of the second component portion;

(c) the planar laminate construction of each of the first and second component portions comprising: (i) a planar foam panel layer having a first face and an opposed second face, (ii) a planar first metal layer having a first face and an opposed second face bonded to the first face of the planar foam panel layer, (iii) a planar second metal layer having a first face bonded to the second face of the planar foam panel layer and an opposed second face; and (iv) a protective layer having an inorganic composition, a first face bonded to the second face of the second metal layer, and an opposed second face;

(d) a first hinge assembly comprising a first hinge portion and a second hinge portion joining the planar first component portion and the planar second component portion along their respective first and second edges, the first hinge assembly adapted to permit the second component portion to rotate relative to the first component portion from a folded position to an unfolded position, with the protective layers of the first and second component portions positioned adjacent to each other when the second component portion is in the unfolded position.

Clause 68. The foldable enclosure component of clause 67, wherein the first component portion includes a first beam reinforcing the laminate construction of the first component portion, with a first end proximate to the first edge, and a second beam reinforcing the laminate construction of the second component portion, with a second end proximate to the second edge and an opposed third end proximate to the third edge.

Clause 69. The foldable enclosure component of clause 68, wherein the first hinge portion and the second hinge portion each comprises:

(i) a base plate with an obverse face, a reverse face, an upper edge, an opposed lower edge and a base plate vertical centerline;

(ii) a hinge section with a hinge section vertical centerline, the hinge section extending from the obverse face and comprising a plurality of spaced-apart hinge leaves symmetrically positioned about the hinge section vertical centerline, with the hinge section vertical centerline being offset from the base plate vertical centerline, each of the plurality of hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures positioned in horizontal alignment with each other along a hinge aperture centerline;

(iii) a locking pin barrel extending from the obverse face and positioned to a first side of the base plate vertical centerline, the locking pin barrel defining a bore;

(iv) a plurality of locking pin leaves extending from the obverse face and positioned to the first side of the base plate vertical centerline, each locking pin leaf defining a locking pin aperture, the locking pin apertures positioned in vertical alignment with each other, and with the bore of the locking pin barrel;

(v) a plurality of free interlock leaves extending from the obverse face, each free interlock leaf defining an interlock aperture, with the interlock apertures in vertical alignment with each other, the free interlock leaves positioned to a second side of the base plate vertical centerline at a position so that, when the second component portion is in the unfolded position relative to the first component portion, the free interlock leaves of each of the first and second hinge portions interleave with the locking pin leaves of the other of the first and second hinge portions; wherein

(e) the hinge leaves of the first hinge portion interleave with the hinge leaves of the second hinge portion, with a hinge pin positioned in the hinge leaf apertures of the interleaved hinge leaves of the first and second hinge portions to pivotally join the first hinge portion and the second hinge portion and permit the second component portion to rotate relative to the first component portion; and the foldable enclosure component further comprises:

(f) a first locking pin adapted to be inserted into the bore defined in the locking pin barrel of the first hinge portion and received in (i) the locking pin apertures of the first hinge portion and (ii) the interlock apertures of the second hinge portion, when the second component portion is in the unfolded position relative to the first component portion.

Clause 70. The foldable enclosure component of clause 69, further comprising a second locking pin adapted to be inserted into the bore defined in the locking pin barrel of the second hinge portion and received in (i) the locking pin apertures of the second hinge portion and (ii) the interlock apertures of the first hinge portion, when the second component portion is in the unfolded position relative to the first component portion.

Clause 71. The foldable enclosure component of either of clause 69 or 70, wherein each of the plurality of spaced-apart hinge leaves of each of the first and second hinge portions has a thickness the same as the other of the plurality of spaced-apart hinge leaves, and the hinge leaves are spaced-apart a distance equal to the thickness.

Clause 72. The foldable enclosure component of clause 71, wherein the hinge section vertical centerline of each of the first and second hinge portions is positioned so that the base plate vertical centerline of the first and second hinge portions is offset from the hinge section vertical centerline an offset distance equal to one-half the thickness of any of the plurality of spaced-apart hinge leaves.

Clause 73. The foldable enclosure component of any one of clause 69, 70, 71 or 72, wherein each locking pin leaf of each of the first and second hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 74. The foldable enclosure component of any of clause 69, 70, 71, 72 or 73, wherein each free interlock leaf of each of the first and second hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 75. The foldable enclosure component of any one of clause 69, 70, 71, 72, 73 or 74, wherein the first end of the first beam is received in one or more positioning tabs extending away from the reverse face of the first hinge portion, which one or more positioning tabs are positioned to conform to a profile of the first end of the first beam, and wherein the second end of the second beam is received in one or more positioning tabs extending away from the reverse face of the second hinge portion, which one or more positioning tabs are positioned to conform to a profile of the second end of the second beam.

Clause 76. The foldable enclosure component of clause 70, wherein the first and second beams each has an “I” shape in profile, the one or more positioning tabs of the first hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile, and the one or more positioning tabs of the second hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile.

Clause 77. The foldable enclosure component of any one of clauses 67-76, wherein the protective layer of the second component portion rotates away from the protective layer of the first component portion when rotating the second component portion relative to the first component portion from a folded position to an unfolded position.

Clause 78. The foldable enclosure component of any one of clause 67-76, wherein the protective layer of the second component portion rotates toward the protective layer of the first component portion when rotating the second component portion relative to the first component portion from a folded position to an unfolded position.

Clause 79. The foldable enclosure component of any one of clauses 67-76, further comprising:

(e) a planar third component portion having a planar laminate construction and a fourth edge positioned proximate to the third edge of the second component portion, the planar laminate construction of the third component portion comprising (i) a planar foam panel layer having a first face and an opposed second face, (ii) a planar first metal layer bonded to the first face of the planar foam panel layer, and (iii) a planar second metal layer having a first face bonded to the second face of the planar foam panel layer and an opposed second face; and (iv) a protective layer having an inorganic composition, a first face bonded to the second face of the second metal layer and an opposed second face, with the protective layers of the second and third component portions positioned adjacent each other when the second and third component portions are in their unfolded positions; and

(f) a second hinge assembly joining the planar second component portion and the planar third component portion along their respective third edge and fourth edge and adapted to permit the third component portion to rotate relative to the second component portion from a folded position to an unfolded position.

Clause 80. The foldable enclosure component of clause 79, wherein the protective layer of the first component portion rotates toward the protective layer of the first component portion when rotating the second component portion relative to the first component portion from a folded position to an unfolded position, and the protective layer of the third component portion rotates away from the protective layer of the second component portion when rotating the third component portion relative to the second component portion from a folded position to an unfolded position.

Clause 81. The foldable enclosure component of either of clause 79 or 80, wherein the third component portion includes a third beam reinforcing the laminate construction of the third component portion, with a fourth end proximate to the fourth edge, and a second hinge assembly joining the planar second component portion and the planar third component portion along their respective third edge and fourth edge adapted to permit the third component portion to be rotated relative to the second component portion from a folded position to an unfolded position.

Clause 82. The foldable enclosure component of clause 81, wherein the second hinge assembly comprises a third hinge portion secured to the third end of the second beam and a fourth hinge portion secured to the fourth end of the third beam, and each of the third hinge portion and the fourth hinge portion comprises:

(i) a base plate with an obverse face, a reverse face, an upper edge, an opposed lower edge and a base plate vertical centerline;

(ii) a hinge section with a hinge section vertical centerline, the hinge section extending from the obverse face and comprising a plurality of spaced-apart hinge leaves symmetrically positioned about the hinge section vertical centerline, with the hinge section vertical centerline being offset from the base plate vertical centerline, each of the plurality of hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures positioned in horizontal alignment with each other along a hinge aperture centerline;

(iii) a locking pin barrel extending from the obverse face and positioned to a first side of the base plate vertical centerline, the locking pin barrel defining a bore;

(iv) a plurality of locking pin leaves extending from the obverse face and positioned to the first side of the base plate vertical centerline, each locking pin leaf defining a locking pin aperture, the locking pin apertures positioned in vertical alignment with each other, and with the bore of the locking pin barrel; and

(v) a plurality of free interlock leaves extending from the obverse face, each free interlock leaf defining an interlock aperture, with the interlock apertures in vertical alignment with each other, the free interlock leaves positioned to a second side of the base plate vertical centerline at a position so that, when the third component portion is in the unfolded position relative to the second component portion, the free interlock leaves of each of the first and second hinge portions interleave with the locking pin leaves of the other of the first and second hinge portions; wherein:

(g) the hinge leaves of the third hinge portion interleave with the hinge leaves of the fourth hinge portion, with a hinge pin positioned in the hinge leave apertures of the interleaved hinge leaves of the third and fourth hinge portions to pivotally join the third hinge portion and the fourth hinge portion and permit the third component portion to rotate relative to the second component portion; and the foldable enclosure component further comprises:

(h) a third locking pin adapted to be inserted into the bore defined in the locking pin barrel of the third hinge portion and received in (i) the locking pin apertures of the third hinge portion and (ii) the interlock apertures of the second hinge portion, when the third component portion is in the unfolded position relative to the second component portion.

Clause 83. The foldable enclosure component of clause 82, further comprising a fourth locking pin adapted to be inserted into the bore defined in the locking pin barrel of the fourth hinge portion and received in (i) the locking pin apertures of the fourth hinge portion and (ii) the interlock apertures of the third hinge portion, when the third component portion is in the unfolded position relative to the second component portion.

Clause 84. The foldable enclosure component of either of clause 82 or 83, wherein each of the plurality of spaced-apart hinge leaves of each of the third and fourth hinge portions has a thickness the same as the other of the plurality of spaced-apart hinge leaves, and the hinge leaves are spaced-apart a distance equal to the thickness.

Clause 85. The foldable enclosure component of clause 84, wherein the hinge section vertical centerline of each of the third and fourth hinge portions is positioned so that the base plate vertical centerline of the third and fourth hinge portions is offset from the hinge section vertical centerline an offset distance equal to one-half the thickness of any of the plurality of spaced-apart hinge leaves.

Clause 86. The foldable enclosure component of any one of clause 82, 83, 84 or 85, wherein each locking pin leaf of each of the third and fourth hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 87. The foldable enclosure component of any one of clause 82, 83, 84, 85 or 86, wherein each free interlock leaf of each of the third and fourth hinge portions has an upper face and a lower face which are curved about the hinge aperture centerline.

Clause 88. The foldable enclosure component of any one of clause 82, 83, 84, 85 or 86, wherein the third end of the second beam is received in one or more positioning tabs extending away from the reverse face of the third hinge portion, which one or more positioning tabs are positioned to conform to a profile of the third end of the second beam, and wherein the fourth end of the third beam is received in one or more positioning tabs extending away from the reverse face of the fourth hinge portion, which one or more positioning tabs are positioned to conform to a profile of the fourth end of the third beam.

Clause 89. The foldable enclosure component of clause 88, wherein the third beam has an “I” shape in profile and the one or more positioning tabs of the third hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile, and the one or more positioning tabs of the fourth hinge portion comprise plural positioning tabs forming a guide frame having an “I” shape in profile.

Clause 90. The foldable enclosure component of any one of clauses 80-89, wherein the hinge aperture centerline of each of the first, second, third and fourth hinge portions is closer to the upper edge of the base plate thereof than to the lower edge thereof.

Clause 91. The foldable enclosure component of clause 90, wherein the first and second hinge portions are respectively oriented so that the hinge aperture centerlines of the first and second hinge portions are closer to the first metal layer of the first and second component portions than to the protective layer of the first and second component portions, and the hinge aperture centerlines of the third and fourth hinge portions are closer to the protective layer of the first and second component portions than to the first metal layer of the first and second component portions.

Clause 92. The foldable enclosure component of clause 91, wherein the hinge aperture centerlines of the first and second hinge portions are positioned a hinge pivot distance from the lower edges of the first and second hinge portions sufficient so that the second component portion can rotate relative to the first component portion at least one hundred eighty degrees from a folded position to an unfolded position.

Clause 93. The foldable enclosure component of clause 92, wherein the hinge aperture centerlines of the third and fourth hinge portions are positioned a hinge pivot distance from the lower edges of the third and fourth hinge portions sufficient so that the third component portion can rotate relative to the second component portion at least one hundred eighty degrees from a folded position to an unfolded position.

Clause 94. The foldable enclosure component of clause 90, wherein the hinge aperture centerlines of the first and second hinge portions extend beyond the first face of the first metal layer of each of the first and second component portions.

Clause 95. The foldable enclosure component of any one of clauses 82-94, wherein the hinge aperture centerlines of the third and fourth hinge portions extend beyond the second face of the protective layer of each of the second and third component portions.

Clause 96. The foldable enclosure component of any one of clauses 82-95, wherein the locking pin leaf of the plurality of locking pin leaves which is proximate the lower edge of each of the third and fourth hinge portions is extended toward the second side thereof to provide a platform tab.

Clause 97. The foldable enclosure component of any one of clauses 67-96, wherein the first hinge assembly is adapted to permit the foldable enclosure component to rotate the second component portion relative to the first component portion from a folded position to an unfolded position at least ninety degrees from the folded position.

Clause 98. The foldable enclosure component of any one of clauses 67-97, wherein the first hinge assembly is adapted to permit the foldable enclosure component to rotate the second component portion relative to the first component portion from a folded position to an unfolded position at least one hundred eighty degrees from the folded position.

Clause 99. The foldable enclosure component of clause 76, wherein the first beam comprises a pair of elongate opposed flanges proximate to the protective layer, and the foldable enclosure component further comprises a pair of elongate insulating members, each of the pair of insulating members defining a channel in which is positioned a respective one of the pair of opposed flanges.

Clause 100. The foldable enclosure component of clause 99, wherein each of the pair of elongate insulating members is polyvinyl chloride.

Clause 101. The foldable enclosure component of clause 67-100, wherein the inorganic composition of every protective layer comprises magnesium oxide.