Patent Publication Number: US-8991105-B2

Title: Collapsible building having rigid walls

Description:
TECHNICAL FIELD 
     The present invention generally relates to buildings that are readily collapsible, erected and transportable. 
     BACKGROUND 
     Temporary housing structures, such as moveable buildings, are typically used when more permanent buildings are impractical. Moveable buildings provide the flexibility of positioning a housing structure in a desired location within a relatively short period of time. However, many moveable buildings are non-collapsible and bulky to transport. Further, some moveable buildings are collapsible to an extent, but not sufficiently collapsible to allow for multiple buildings to be transported. Accordingly, there exists a need for readily collapsible buildings that form a structure when erected. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Referring now to the drawings, preferred illustrative embodiments are shown in detail. Although the drawings represent some embodiments, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description. 
         FIG. 1  is a side view of a building according to an embodiment. 
         FIG. 2  is an end view of the building of  FIG. 1 , illustrating multiple embodiments. 
         FIG. 3  is a view similar to  FIG. 2 , illustrating a portion of the building in multiple configurations for clarity. 
         FIG. 4  is a view similar to  FIG. 2 , illustrating a portion of the building in multiple configurations for clarity. 
         FIG. 5  is a view similar to  FIG. 1 , illustrating some portions in other configurations and other portions of the building in multiple configurations for clarity. 
         FIG. 6  is a top view of the frame according to an embodiment, taken along line  6 - 6  of  FIG. 1 . 
         FIG. 7  is an enlarged view of portion  7  of  FIG. 2 . 
         FIG. 8  is an exploded view of an embodiment of a biasing assembly. 
         FIG. 9  is a partial view of the assembly of  FIG. 8 . 
         FIG. 10  is an enlarged view of portion  10  of  FIG. 1 . 
         FIG. 11  is a top view of the view of  FIG. 10 . 
         FIG. 12  is a side view illustrating multiple buildings according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     As best seen in at least one of  FIGS. 1-5 , a building  20  is illustrated. Building or structure  20  includes a foundation  22 , a generally planar front wall  24 , a generally planar back wall  26 , a generally planar first side wall  28 , a generally planar second side wall  30 , and a roof  32 . Walls  24 ,  26 ,  28 ,  30  each have a collapsed position or configuration in which it is substantially horizontal, and an erected position or configuration in which it is substantially vertical, as clearly shown in  FIGS. 3-5 . As best seen in at least one  FIGS. 1 ,  2 , and  6 , foundation  22  includes a plurality of standoff assemblies  38  interconnected by a base, or frame,  40  that includes rails  42  that extend beyond the front wall  24  and the back wall  26 . Frame  40  also includes tubes  44 , cross members  46  and end members  48 . As illustrated, the rails  42  and cross members  46  interconnect the tubes  44  and end members  48  to provide a base for the building  20 . A floor panel  50  ( FIG. 1 ) is positioned above the frame  40 . Frame  40  further includes a front wall extension  52 , a back wall extension  54 , a first side extension  56 , and as second side extension  58  extending upward therefrom. 
     The front wall  24  includes an inner frame (not numbered) that supports opposing panels (not numbered). The front wall  24  is generally defined by an outer front surface  60 , an inner front surface  62 , a lower front end  64 , an upper front end  66 , a first front side  68 , a second front side  70 , a door opening  72 , and a plurality of window openings  74 . Door opening  72  has a door  80  coupled thereto and each window opening  74  has a window  82  coupled thereto. As illustrated, the lower front end  64  is rotatably attached to the front wall extension  52  with a front hinge  88 . Thus, front wall  24  is rotatably attached to base or frame  40 . 
     The back wall  26  includes an inner frame (not numbered) that supports opposing panels (not numbered). The back wall  26  is generally defined by an outer back surface  90 , an inner back surface  92 , a lower back end  94 , an upper back end  96 , a first back side  98 , a second back side  100 , and a plurality of openings (not shown). Each opening may have a breaker box, air conditioner, or other operable item attached thereto. The lower back end  94  is rotatably attached to the back wall extension  54  with a back hinge  108 . Thus, back wall  26  is rotatably attached to base or frame  40 . 
     Similarly, the first side wall  28  includes an inner frame (not numbered) that supports opposing panels (not numbered). The first side wall  28  is generally defined by a generally planar outer surface  120 , a generally planar inner surface  122 , a lower end  124 , an upper end  126 , a front side  128 , and a back side  130 . The lower end  124  is rotatably attached to a first side extension  56  with a side hinge  138 . Thus, first side wall  28  is rotatably attached to base or frame  40 . 
     Additionally, the second side wall  30  includes an inner frame (not numbered) that supports opposing panels (not numbered). The second side wall  30  is generally defined by a generally planar outer surface  140 , a generally planar inner surface  142 , a lower end  144 , an upper end  146 , a front side  148 , and a back side  150 . The lower end  144  is rotatably attached to a second side extension  58  with a side hinge  158 . Thus, second side wall  30  is rotatably attached to base or frame  40 . From the foregoing, and with reference to  FIGS. 3-5 , it can be clearly understood that each of walls  24 ,  26 ,  28 ,  30  has angular movement relative to base or frame  40  between its respective collapsed and erected position or configuration; and that each of walls  24 ,  26 ,  28 ,  30  superposes base or frame  40  and roof  32  in its respective collapsed position or configuration, and extends between base or frame  40  and roof  32  in its respective erected position or configuration. The superposition of each of collapsed walls  24 ,  26 ,  28 ,  30  relative to base  40  or roof  32 , is understood to mean its respectively overlying or underlying the base or the roof, directly or indirectly, as shown, for example, in  FIGS. 2-5 . 
     The roof  32  includes a generally planar roof outer surface  170 , an opposing generally planar roof inside surface  172 , a front edge  174 , a back edge  176 , a first side edge  178 , and a second side edge  180 . In the embodiment illustrated, the front edge  174  and the back edge  176  have an overhang  190  with a track  192  attached thereto. Each track  192  has a first end  194  and a second end  196  ( FIGS. 1 and 5 ). 
     As best seen in  FIG. 2  with greater detail in  FIG. 7 , the first side wall  28  and the second side wall  30  each include a pair of guide rollers  198  extending therefrom. Guide rollers  198  each include a wheel  200 , a stem  202 , and a bearing  204  rotatably connecting the wheel  200  and the stem  202 . Stems  202  are attached to the first side wall  28  and the second side wall  30  with wheels  200  interposed within tracks  192 , generally as illustrated. Preferably, the axes of stems  202  and wheels  200  are generally parallel with the tubes  44 , and generally perpendicular to the extension, of the track  192  from the first end  194  to the second end  196 . Other embodiments include a guide roller without a bearing  204 , where the wheel  200  is made of nylon or other low-friction materials. From the foregoing, and with reference to  FIGS. 5 and 7 , those of ordinary skill in the art will clearly recognize that the first and second side walls  28 ,  30  are guidingly coupled to roof  32  through the operative engagement of the side wall guide rollers and the roof tracks, and in response to angular movement of the side walls  28 ,  30  between their collapsed and erected positions or configurations, the roof  32  is moved between its lowered and raised positions, respectively. In other words, the roof is guidingly coupled to both the first and second side walls, and has movement relative to the base guided by angular movement of the first and second side walls between their collapsed and erected configurations, as one of ordinary skill in the art will appreciate from an inspection of the drawings. 
     As best seen in  FIG. 3 , and embodiment of building  20  includes cables  210  that are connected to the front wall  24 , routed over the roof  32 , and connected to the back wall  26  via a pair of linearly adjustable turnbuckles  212 . Turnbuckles  212  assists in collapsing, erecting, and stabilizing the building  20 , such as discussed herein. Squaring cables  216  ( FIG. 1 ) may interconnect the side walls  28 ,  30  with the frame  40  to further stabilize the building  20  when fully erected. Preferably, fastening assemblies (not shown) rigidly interconnect the front wall  24 , back wall  26 , first side wall  28 , second side wall  30 , and roof  32 . 
     As best illustrated in  FIGS. 2 ,  5 , the building  20  also includes a pair of biasing assemblies  220  to urge the roof  32 , the first side wall  28 , and the second side wall  30  into an erected configuration, as discussed in greater detail below. Building  20  is illustrated in a fully erected configuration in  FIG. 1  and a fully collapsed configuration in  FIG. 12 .  FIG. 5  illustrates building  20  in an intermediate configuration, the fully erected configuration, and the fully collapsed configuration. As discussed in greater detail below,  FIGS. 2 and 5  each illustrate a vertically bisected half of two embodiments of the biasing assembly  220  juxtaposed in relation to the first side wall  28  and the roof  32 , with the illustrations of each of  FIGS. 2 and 5  discussed herein as though each embodiment is a complete biasing assembly  220 , with a vertically bisected half adjacent an identical, minor image vertically bisected half of each embodiment. 
     Briefly, an embodiment of collapsing the building  20  is as follows. Building  20 , as best seen in  FIGS. 1 ,  2 , and  3 , is in the fully erected configuration. Turnbuckles  212  and other fastening assemblies (not shown) that restrain the front wall  24  are detached, and the front wall  24  is rotated relative the frame  40  and front wall extension  52 . In one embodiment, the inner surface  62  contacts the floor panel  50 . The center of rotation is generally along the axis of front hinge  88 . Cables  210  may be used to lower the front wall  24  into a fully collapsed configuration FC illustrated in phantom in  FIG. 3 . In one embodiment of the fully collapsed configuration of the front wall  24 , the inner front surface  62  contacts the floor panel  50 . As shown in  FIGS. 3 and 4 , front wall  24  in its collapsed position or configuration superposes base or frame  40  and roof  32 . 
     Then, the fastening assemblies (not shown) that restrain the back wall  26  are detached, and the back wall  26  is rotated relative the frame  40  and back wall extension  54  into a fully collapsed configuration BC illustrated in phantom in  FIG. 4 . The center of rotation is generally along the axis of back hinge  108 . As illustrated, the front wall extension  52  extends above the frame  40  a distance about equal to the width of the front wall  24 , and the back wall extension  54  extends above the frame  40  a distance about equal to the width of the front wall  24  plus the width of the back wall  26 . In one embodiment of the fully collapsed configuration of the back wall  26 , the inner back surface  92  contacts the outer front surface  60 . As shown in  FIGS. 3 and 4 , back wall  26  in its collapsed position or configuration superposes base or frame  40  and roof  32 . 
     Then, the fastening assemblies (not shown) that restrain the first side wall  28 , second side wall  30 , and roof  32  are detached, and the roof  32  is lowered, as illustrated in phantom in  FIG. 5 . As roof  32  is lowered, the first side wall  28  is rotated relative the frame  40  and first side extension  56 , and the second side wall  30  is rotated relative the frame  40  and second side extension  58  into a fully collapsed configuration RC illustrated in phantom in  FIG. 5 . The center of rotation for the first side wall  28  is generally along the axis of side hinge  138 . The center of rotation for the second side wall  30  is generally along the axis of side hinge  158 . As shown in  FIG. 5 , the front and back walls  24 ,  26  are disposed between base  40  and the collapsed side walls  28 ,  30  which are guidingly coupled to roof  32  through guide rollers  198  and tracks  192 . Thus, the front and back walls  24 ,  26  are moveable between their respective collapsed and erected positions or configurations only when side walls  28 ,  30  are both in their erected position or configuration and roof  32  is consequently in its raised position, as one of ordinary skill in the art will immediately appreciate. Moreover, those of ordinary skill in the art will clearly recognize that the guide rollers  198  of one of first and second side walls  28 ,  30  may move along tracks  192  independently of the guide rollers  198  of the other side wall  28 ,  30 , and understand that the angular movements of the first and second side walls  28 ,  30  relative to the base or frame  40  are therefore independent of each other. In other words, one side wall  28 ,  30  may be moved angularly relative to frame or base  40  between its collapsed and erected positions or configurations while the other side wall  28 ,  30  remains erected or collapsed or at positions therebetween. Roof  32  would then, of course, assume angular orientations other than being horizontal or parallel with base or frame  40  as shown in  FIG. 5 , during its raising and lowering, as one of ordinary skill in the art will immediately understand. Thus, the roof  32  is guidingly coupled to both the first and second side walls  28 ,  30 , and its movement relative to base  40  is guided by the angular movement of the side walls  28 ,  30  between their collapsed and erected positions or configurations. 
     As roof  32  is lowered, the guide rollers  198  are guided within tracks  192  and building  20  may collapse generally as shown in the phantom illustrations of  FIG. 5 , which depicts by example the case of substantially simultaneous collapsing movement of sidewalls  28  and  30 . Additionally, as the roof  32  is lowered, and the first side wall  28 , second side wall  30  rotate, the biasing assemblies  220  urgingly resist at least a portion of the weight of first side wall  28 , second side wall  30 , and roof  32 . Thus provided, the biasing assemblies  220  assist an operator or operators in collapsing the building  20 , as the entire weight of the portions of the building  20  being collapsed need not be physically resisted. As best seen in  FIGS. 5 and 12 , the building  20  may be readily collapsed to a fully collapsed configuration where the foot print of the building  20  has not changed, and the height has been reduced to about a minimum. 
     When fully collapsed, the building  20  may be transported with a conventional forklift via tubes  44  and/or stacked for storage or transportation, as illustrated in  FIG. 12 . When fully collapsed, the internal features of the building  20 , such as a breaker box, internal wiring, electrical outlets (not shown), may be protected from the weather by the overhang  190  and roof  32 . Additionally, the biasing assemblies  220  are protected by the overhang  190  and roof  32 . 
     An embodiment of converting the building  20  from the fully collapsed configuration of  FIG. 12  to the fully erected configuration of  FIG. 1  is as follows. The roof  32  is raised, with assistance of the biasing assemblies  220 , thereby rotating the first side wall  28  and the second side wall  30  into a fully erected configuration RE, as shown in  FIG. 5 . The biasing assemblies  220  may restrain the first side wall  28 , the second side wall  30 , and the roof  32  in the fully erected configuration, or fasteners may be used to secure the first side wall  28  and the second side wall  30  to roof  32 . The back wall  26  is then raised until the upper back end  96  is adjacent the roof  32 . Cables  210  may then be used to raise the front wall  24  to the fully erected configuration of  FIG. 1 . The cables  210  may then be routed over the roof  32  and secured to turnbuckles  212 . Additional fasteners may then be used to secure the building  20 , if desired. Additional items, such as air conditioner may be then attached to the building  20 . 
     As best illustrated in  FIGS. 2 ,  5  and  8 , an embodiment of the biasing assembly  220  includes a torsional assembly  230 . Torsional assembly  230 , as shown generally in  FIG. 2  and in detail in  FIG. 8 , includes a torsion shaft  232  which spans between side bearing brackets  234  which contain bearings  236  that support torsion shaft  232  and allow torsion shaft  232  to rotate freely. While torsion shaft  232 , as illustrated, extends the entire width of the first side wall  28  and the second side wall  30 , torsion shaft  232  may have one or more sections that are connected in a manner that will allow torque to be transmitted between each section. Torsion shaft  232  may also be supported by intermediate bearing brackets  238  which contain bearings (not numbered) and allow torsion shaft  232  to rotate freely within the bracket bearing. Each torsional assembly  230  is generally located adjacent the first side edge  178  ( FIG. 2 ) or the second side edge  180  ( FIG. 5 ). A pair of torsion springs  240  are positioned on the torsion shaft  232 . 
     A spring winding cone  242  circumscribes torsion shaft  232  and selectively locks against torsion shaft  232  to prevent rotation so that spring winding cone  242  may be rotated to pre-tension spring  240  and may thereafter be locked against rotation so as to maintain the pre-tension force. Spring  240  connects to winding cone  242  at the inner end of spring  240  with a torsionally rigid connection such that when winding cone  242  is rotated, torsion in spring  240  will increase or decrease depending on the direction of rotation. Spring  240  is also torsionally rigidly attached, at its outer end, to an anchor cone  244  which is bolted to an anchor bracket  246  which bends around cable drum  250  ( FIG. 9 ) and attaches to bearing bracket  234 . Once installed, the outer ends of springs  240  remain rotationally fixed to anchor brackets  246  and bearing brackets  234 . Each of the anchor brackets  246  and bearing brackets  234  may be fastened to the roof  32  with fasteners, such as bolts. A pair of cable drums  250  are torsionally rigidly attached to torsion shaft  232 . A cable  252  winds around each cable drum  250  as torsion shaft  232  is rotated, as discussed in greater detail below. 
     As shown in  FIG. 5  distal ends  254  of cables  252  are attached to the upper ends  126 ,  146  of side walls  28 ,  30  and the opposing ends of cables  252  are wrapped around the cable drums  250 . As the building  20  is collapsed, as discussed in greater detail herein, the cables  252  unwind from the cable drums  250 , as distal ends  254  and upper ends  126 ,  146  move away from the cable drums  250 , thereby twisting the springs  240  around the torsion shafts  232  and increasing the torsion in the springs  240  and the energy stored within the springs  240 . Thus it may be said that each biasing assembly  220  has first and second states respectively corresponding to the collapsed and erected positions or configurations of the associated side wall  28 ,  30 , in which it has relatively greater and lesser amounts of stored energy. A properly adjusted torsional assembly  230  will exert a generally horizontal force through cables  252  on either the first side wall  28  or the second side wall  30  that is adequate to allow a user to erect the building  20  with the slightest of lifting effort, due to the biasing assembly  220  urging the side walls  28 ,  30  and roof  32  of structure  20  into their erected or raised positions. 
     As also illustrated in  FIGS. 2 and 5 , another embodiment of the biasing assembly  220  includes an axial assembly  330 .  FIG. 1  illustrates an embodiment with a pair of axial assemblies  330 , with one axial assembly  330  positioned at least partially within the first side wall  28 , and another axial assembly  330  positioned at least partially within the second side wall  30 . Axial assembly  330  includes an anchoring rod  332  and a pulley rod  334  secured within each of the side walls  28 ,  30 . The anchoring rod  332  is positioned just above the side extensions  56 ,  58 , and the pulley rod  334  is positioned just below the upper ends  126 ,  146  of side walls  28 ,  30 . Cables  336  interconnect the pulley rod  334  and the roof  32 . Each cable  336  is routed around a spring pulley  338 . A spring  340  extends between the spring pulley  338  and the anchoring rod  332 . As best seen in  FIG. 5 , the pulley rod  334  has a pulley  350  attached thereto, with the cable  336  guided thereon. Each cable  336  has a proximal end  352  attached to the pulley rod  334 , then a length extending to the spring pulley  338 , then extending at least partially around the spring pulley  338 , then a length extending from the spring pulley  338  to the pulley  350 , then extending at least partially around the pulley  350 , and then a length extending from the pulley  350  to the roof  32 , adjacent one of the side edges  178 ,  180 . 
     As roof  32  is lowered, the guide rollers  198  are guided within tracks  192  away from the side edges  178 ,  180  of the roof  32  as the pulleys  350  are moved away from the side edges  178 ,  180 . During this movement, the length of cable  336  between the pulley  350  and the roof  32  is increased, thereby decreasing the length between the pulley  350  and the spring pulley  338 . As the length between the pulley  350  and the spring pulley  338  is decreased, the spring  340  is expanded, increasing the tension in the spring  340  and the energy stored within the spring  340 , and thereby exerting a biasing force on the pulley  350  that urges the upper ends  126 ,  146  of side walls  28 ,  30  apart and toward the fully erected position illustrated in  FIG. 1 . Thus it may be said that each biasing assembly  220  has first and second states respectively corresponding to the collapsed and erected positions or configurations of the associated side wall  28 ,  30 , and in which it has relatively greater and lesser amounts of stored energy, respectively. In this manner, the axial assemblies  330  urge the roof  32  upward and assist a user or users in collapsing the building  20  as the entire weight of the first side wall  28 , the second side wall  30  and the roof  32  need not be supported in order to lower the roof  32  to the fully collapsed configuration of  FIG. 12 . Additionally, the axial assemblies  330  assist a user when erecting the building  20 , as the springs  340  biasingly urge the roof  32  away from the frame  40 . 
     Furthermore, the axial assemblies  330  and/or the torsional assemblies  230  can be preloaded with springs  240 ,  340  distorted when the building  20  is in the fully erected configuration of  FIGS. 1 and 2 , such that less effort is required to raise the roof  32 . To preload a biasing assembly  220 , a spring  240 ,  340  is preloaded to provide a desired amount of force to urge the roof  32  away from the frame  40  at least partially when the building  20  is transformed from the fully collapsed configuration to the fully erected configuration. 
     Preferably, the hinges  88 ,  108 ,  138  and  158  are continuous, ‘piano’ hinges with an axial hinge rod (not shown) that extends the length of the hinge. Also preferably, any electrical wiring extending from the walls to the floor are routed through flexible conduits that avoid pinch points of the wall to frame connections. 
     As best seen in  FIGS. 10 and 11 , each standoff assembly  38  includes a frame end attachment  400 , having a support member, or a supporting tube,  402  interposed therein. Each supporting tube  402  includes an upper end  404  and a lower base cap  410  attached to an opposing end. In the embodiment illustrated, the lower base cap  410  has an opening  412  defined by a horizontal abutting surface  414  and a contoured vertical surface  416  formed therein. The horizontal abutting surface  414  and the contoured vertical surface  416  are sized to matingly receive the upper end  404  of another standoff assembly  38 , as best seen in  FIG. 12 . The supporting tubes  402  each include a plurality of adjustment apertures  420  formed generally horizontally. Each standoff assembly  38  also includes an adjustment pin  422 . Each frame end attachment  400  includes a pair of pin apertures  430  formed therein. 
     As will be appreciated, the supporting tube  402  may be guided vertically within the frame end attachment  400  and releasably secured in position by inserting adjustment pin  422  through pin apertures  430  and one of the adjustment apertures  420 . In this manner, the supporting tubes  402  of a building  20  may be adjusted (preferably to a lower adjustment location as illustrated in  FIG. 12 ) for transportation of building  20 . Furthermore, the supporting tubes  402  of a building  20  may be adjusted to other adjustment apertures  420  positions when erecting building  20  on a surface of constant or varying grade, or when positioning a building  20  at a desired height above grade. 
     Additionally, buildings  20  may be stacked when in the fully collapsed configuration, as best seen in  FIG. 12 . To securely stack buildings  20 , the supporting tubes  402  are adjusted to a lower adjustment location and each lower base cap  410  of a building  20  is positioned over an upper end  404  of another building  20 , as shown in the embodiment illustrated. 
     The preceding description has been presented only to illustrate and describe exemplary embodiments of the methods and systems of the present invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. The invention may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. The scope of the invention is limited solely by the following claims.