Patent Abstract:
A folding modular structure is described. The structure typically includes a top panel, which is ultimately the roof deck. Two side panels, a front and a rear panel are connected to the top panel by pivoting mechanisms so that the side, front and rear panels can fold open to create the modular structure. Spacer panels are connected between three of the four total side, front and rear panels. The spacer panels are necessary to provide clearance so that each of the panels can be folded onto the other already folded panels. In the folded configuration, shipping many more modular structures to final destinations is possible.

Full Description:
BACKGROUND 
   I. Field of the Invention 
   The present invention relates generally to the field of buildings and structures and, more particularly, to a folding modular structure. 
   II. Description of the Related Art 
   Modular structures have a variety of used in many industries. For example, remote sensing stations for meteorological towers or cellular towers require structures to house equipment and allow operators shelter. The military also uses structures for communications stations and the like. Another use of modular structures is for detention centers. Often times, jails and detention centers are created by stacking several individual prefabricated cells side by side and on top of one another to form a detention center. As stated these modular cells are prefabricated and often include all four walls and a floor. The cells can further include necessary reinforcements and hardware necessary for a detention cell. These cells are prefabricated at a suitable facility and then transported, typically by flatbed truck to their final destinations, which could include ships for overseas transport. 
     FIG. 1A  illustrates a prior art flat bed transport truck  10  having a flat bed trailer  15  transporting prior art modular structures  20 . The structures  20  are shown face to face or rear to rear displaying the side walls on the sides of the trailer  15 . Typically, only three or four of the structures, which can weigh anywhere up to 30,000 pounds, can be placed on the trailer  15 . It is typically time consuming and very expensive to be able to only ship three of four of the cells at a time. 
   SUMMARY 
   In general, the invention features a folding modular structure. The structure typically includes a top panel, which is ultimately the roof deck. Two side panels, a front and a rear panel are connected to the top panel by pivoting mechanisms so that the side, front and rear panels can fold open to create the modular structure. Spacer panels are connected between three of the four total side, front and rear panels. The spacer panels are necessary to provide clearance so that each of the panels can be folded onto the other already folded panels. In the folded configuration, shipping many more modular structures to final destinations is possible. 
   In general, in one aspect, the invention features a modular structure, including a top panel having four sides, a first spacer panel connected generally perpendicular to a first side of the top panel, a first panel pivotally connected to the first spacer panel, a second spacer panel connected generally perpendicular to a second side of the top panel, a second panel pivotally connected to the second spacer panel, a third spacer panel connected generally perpendicular to a third side of the top panel, a third panel pivotally connected to the third spacer panel and a fourth panel pivotally connected to a fourth side of the top panel. 
   In one implementation, the third spacer panel is wider than the second spacer panel and the second spacer panel is wider than the first spacer panel. 
   In another implementation, the width of the third spacer panel is generally equal to the sum of the thicknesses of the first, second and fourth panels. 
   In another implementation, the first spacer panel and the first panel are coplanar, the second spacer panel and second panel are coplanar and the third spacer panel and the third panel are coplanar. 
   In another implementation, two of the first, second, third and fourth panels are side walls of the structure, one of the first, second, third and fourth panels is the front wall of the structure and one of the first, second, third and fourth panels is the rear wall of the structure. 
   In still another implementation, the first, second, third and fourth panels generally have a thickness T. 
   In yet another implementation, the first spacer panel generally has a width T. 
   In another implementation, the second spacer panel generally has a width 2 times T. 
   In another implementation, the third spacer panel generally has a width 3 times T. 
   In another implementation, the second and third spacer panels are generally parallel and the first spacer panel is generally perpendicular to the second and third spacer panels. 
   In another implementation, the second and third panels are side walls of the structure, the first panel is a rear wall of the structure and the fourth panel is a front wall of the structure. 
   In another aspect, the invention features a structure apparatus, including a roof deck, side walls connected to the roof deck, a front wall connected to the roof deck and to the side walls and a rear wall connected to the roof deck and the side walls. 
   In one implementation, the apparatus further includes a first elongated spacer panel connected between at least one of the side walls, the front wall and the rear wall, a second elongated spacer panel connected between at least one of the side walls, the front wall and the rear wall and a third elongated spacer panel between at least one of the side walls, the front wall and the rear wall. 
   In one implementation, the spacer panels are pivotally connected to the respective wall. 
   In another implementation, the first spacer panel is wider than the second spacer panel and the second spacer panel is wider than the third spacer panel. 
   In another implementation, the width of the first panel and respective wall is equal to the width of the second spacer panel and respective wall and further equal to the width of the third spacer panel and respective wall. 
   In another implementation, at least one of the side walls, the front wall and the rear wall is connected directly to the roof deck. 
   In still another aspect, the invention features a method of installing a modular structure, providing a folding modular structure having a top panel, side panels, a front panel and a rear panel, the panels facing upward, inverting the structure thereby allowing the panels to unfold, forming side walls, a front wall and a rear wall, lowering the structure onto a base, affixing the structure to the base, securing the panels to respective panels and adding hardware to the structure. 
   In one implementation, the methods further includes adding additional structures to the first structure. 
   In another implementation, the method further includes forming a detention center from a plurality of structures. 
   One advantage of the invention is that several more structures can be shipped to final destinations as compared to conventional structures. 
   Another advantage is that single structures can more easily be transported to remote and difficult to reach destinations. 
   Other objects, advantages and capabilities of the invention will become apparent from the following description taken in conjunction with the accompanying drawings showing the preferred embodiment of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  illustrates a prior art flat bed transport truck having prior art modular structures; 
       FIG. 1B  illustrates a flat bed transport truck having embodiments of a folding modular structure; 
       FIG. 1C  illustrates a perspective side view of an embodiment of a folding modular structure in a first position; 
       FIG. 2  illustrates a perspective side view of an embodiment of a folding modular structure in a second position; 
       FIG. 3  illustrates a perspective side view of an embodiment of a folding modular structure in a third position; 
       FIG. 4  illustrates a perspective side view of an embodiment of a folding modular structure in a fourth position; 
       FIG. 5  illustrates a perspective side view of an embodiment of a folding modular structure in a fifth position; 
       FIG. 6  illustrates a perspective rear view of an embodiment of a folding modular structure in a sixth position; 
       FIG. 7  illustrates a perspective front view of an embodiment of a folding modular structure in a seventh position; 
       FIG. 8  illustrates a perspective front view of an embodiment of a folding modular structure in an eighth and final open position; 
       FIG. 9  illustrates a perspective view rear view of an embodiment of a folding modular structure in an open position; 
       FIG. 10  illustrates a close up view of a lower corner of an embodiment of a folding modular structure; 
       FIG. 11  illustrates a partial cut-away top view of an embodiment of a folding modular structure; 
       FIG. 12  illustrates a partial cut-away side view of an embodiment of a folding modular structure; 
       FIG. 13  illustrates a front view of an embodiment of a folding modular structure; 
       FIG. 14  illustrates a top view of two embodiments of a folding modular structure placed side by side; 
       FIG. 15  illustrates a front view of two embodiments of a folding modular structure placed side by side; and 
       FIG. 16  illustrates a partial cut-away top view of interconnection hardware. 
   

   DETAILED DESCRIPTION 
   Referring to the drawings wherein like reference numerals designate corresponding parts throughout the several figures, reference is made first to  FIG. 1B  illustrates a flat bed transport truck having embodiments of a folding modular structure  100 . As is further appreciated in the description below, up to 32 of the embodiments of folding modular structures  100  can be placed on the trailer  15  of a flatbed truck  10 . The structures  100  are typically loaded onto the trailer  15  upside down so that the folding panels (see below) do not prematurely unfold. When the structures  100  are ready for placement, they are inverted so that the force of gravity is allowed to unfold the panels. 
   In  FIG. 1C  and the several figures that follow, the cell  100  has been inverted so that it can unfold into a fully open position as is now described. Typically, a crane, large forklift or other suitable lifting mechanism can lift and invert the structure  110  into the inverted position to allow the panels to unfold into the open position. Typically, cables or other suitable rigging  75  can be connected to the four corners  101 ,  102 ,  103 ,  104  of the structure  100  in order to lift, invert and unfold the panels of the structure  100 . 
     FIG. 1C  illustrates a perspective side view of an embodiment of a folding modular structure  100  in a first position. The structure  100  generally includes a top panel  105  that is ultimately the roof of the structure  100 . The structure  100  further includes side panels  110 ,  115  that are shown in a “folded-under” position. Each side panel  110 ,  115  is connected to a respective elongated side spacer panel  120 ,  125  that are connected generally perpendicular to respective sides of the top panel  105 . As is further illustrated and described below with respect to  FIG. 13 , the side panels  110 ,  115  are pivotally connected to the respective side spacer panel  120 ,  125 . In this folded first position, the side panels  110 ,  115  are generally parallel to the top panel  105  and generally perpendicular to the side spacer panels  120 ,  125 . Furthermore, there are certain dimensional relationships among the side panels  110 ,  115  and the side spacer panels  120 ,  125  that enables the structure  100  to be folded onto itself. 
     FIG. 2  illustrates a perspective side view of an embodiment of a folding modular structure  100  in a second position. In this second position the first side panel  110  is unfolding in the direction of arrow A into its open position. Typically, the side panel  110  impinges the motion of the side panel  115  (and the front and rear panels as described with respect to  FIGS. 6–7 ). However, once the side panel  110  unfolds, the side panel  115  typically also begins to unfold. 
     FIG. 3  illustrates a perspective side view of an embodiment of a folding modular structure  100  in a third position. In this third position, the side panel  110  is fully open and generally adjacent and oriented parallel (and co-planar) to the side spacer panel  120  and perpendicular to the top panel  105 . Typically the panel  110  is still free to rotate slightly with respect the side spacer panel  120 . However, gravity keeps the side panel  110  fully unfolded. 
     FIG. 4  illustrates a perspective side view of an embodiment of a folding modular structure  100  in a fourth position. In this fourth position the second side panel  115  is unfolding in the direction of arrow B into its open position. Typically, the side panel  110  impinges the motion of the front and rear panels (see  FIGS. 6–7  below). However, once the side panel  110  unfolds, the other panels typically also begin to unfold. 
     FIG. 5  illustrates a perspective side view of an embodiment of a folding modular structure  100  in a fifth position. In this fifth position, the side panel  115  is fully open and generally adjacent and oriented parallel (and co-planar) to the side spacer panel  125  and perpendicular to the top panel  105 . Furthermore, the side panels  110 ,  115  are generally parallel to each other and are ultimately the side walls of the structure  100 . Typically the panel  115  is still free to rotate slightly with respect the side spacer panel  125 . However, gravity keeps the side panel  115  fully unfolded. 
     FIG. 6  illustrates a perspective rear view of an embodiment of a folding modular structure  100  in a sixth position. In this sixth position the rear panel  130  is unfolding in the direction of arrow C into its open position. It is now illustrated that the rear panel  130  is pivotally connected to a rear spacer panel  135  similar to how the side panels  110 ,  115  are respectively connected to the side spacer panels  120 ,  125 . Typically, the rear panel  130  continues to impinge the motion of the front panel (see  FIG. 7  below). However, once the rear panel  130  unfolds, the front panel typically also begins to unfold. Although a separate figure is not used to illustrate the rear panel  130  fully unfolded, once the rear panel  130  unfolds, it is in its fully open position and generally adjacent and oriented parallel (and co-planar) to the rear spacer panel  135  and perpendicular to the top panel  105 . Furthermore, the rear panel  130  is generally perpendicular to the side panels  110 ,  115  and is ultimately the rear wall of the structure  100 . Typically the rear panel  130  is still free to rotate slightly with respect the side spacer panel  135 . However, gravity keeps the rear panel  130  fully unfolded. 
     FIG. 7  illustrates a perspective front view of an embodiment of a folding modular structure  100  in a seventh position. In this seventh position the front panel  140  is unfolding in the direction of arrow D into its open position. It is now illustrated that the front panel  140  is pivotally connected directly to the front end of the top panel  105 , unlike the rear panel  130  and side panels  110 ,  115  that are all respectively connected to a spacer panel  120 ,  125 ,  135 . Typically, the front panel  140  is the last panel to unfold and therefore impinges no motion of any other panel. Although a separate figure is not used to illustrate the front panel  140  fully unfolded, once the front panel  140  unfolds, it is in its fully open position and generally perpendicular to the top panel  105 . Furthermore, the front panel  140  is generally perpendicular to the side panels  110 ,  15 , and generally parallel to the rear panel  130  and is ultimately the front wall of the structure  100 . Typically, as with the other panels  110 ,  15 ,  130 , the front panel  140  is still free to rotate slightly with respect the top panel  105 . However, gravity keeps the front panel  140  fully unfolded. 
   The figures above describe the basic motion of the panels as they unfold until the structure  100  is in a fully open position. It is appreciated that once the folded structure is removed from the flatbed truck and inverted as described above, it is the force of gravity that exerts the necessary torques on the panels so that they rotate with respect to the top panel to be unfolded. The above described figures illustrate that each panel unfolds while the other panels stay stationary. These figures are shown in this manner for illustrative purposes. It is understood that the force of gravity is exerted on all the panels simultaneously and that they may unfold and slide passed each other in a variety of ways. 
     FIG. 8  illustrates a perspective front view of an embodiment of a folding modular structure  100  in an eighth and final open position. In this view, the structure  100  is still supported by the rigging  75 . Furthermore, as described above, the structure  100  typically is placed on a slab or other base and must be properly plumbed, squared and otherwise secured. In order to secure the panels  110 ,  115 ,  130 ,  140  with respect to each other suitable brackets  150  are secured on the lower four corners  106 ,  107 ,  108 ,  109  of the structure  100 . Furthermore, each of the panels  110 ,  115 ,  130 ,  140  may be fitted with hardware or other dressing such as a window  142  and a door  143  as shown on front panel  140 . 
     FIG. 9  illustrates a perspective view rear view of an embodiment of a folding modular structure  100  in an open position. In this view, the structure  100  no longer supported by the rigging  75 . This rear view shows the brackets  150  on the four corners  106 ,  107 ,  108 ,  109  of the structure  100 . 
     FIG. 10  illustrates a close up view of a lower corner  108  of an embodiment of a folding modular structure  100 . This view illustrates the lower corner  108  for illustrative purposes. It is understood that the other lower corners  106 ,  107 ,  109  are similarly oriented. The bracket  150  is shown securing the rear panel  130  and the side panel  110 . Suitable connecting devices  151  such as bolts are used to secure the bracket  150  to the panels  110 ,  130 . 
   The following figures illustrate several dimensional and spatial orientations of the embodiment of the structure  100  as described above. 
     FIG. 11  illustrates a partial cut-away top view of an embodiment of a folding modular structure  100 . The top panel  105  is only partially shown in order to illustrate the overlapping relationship of the front and fear panels  140 ,  130  when the structure  100  is in the folded position. The dotted line  142  illustrates that the forward edge of the rear panel  130  is folded underneath the front panel  140 . As is now illustrated the front panel  140  is pivotally connected to the top panel  105  by a suitable pivoting device  141  such as a hinge or roller. Similarly, the rear panel  130  is pivotally connected to the rear spacer panel  135  by a suitable pivoting device  131  such as a hinge or roller. The side spacer panels  126 ,  125  are also shown. 
     FIG. 12  illustrates a partial cut-away side view of an embodiment of a folding modular structure  100 . As described above, the front panel  140  is pivotally connected to the forward end of the top panel  105  by pivoting device  141 . The front panel  140  is shown in the fully folded position. The rear panel  130  is pivotally connected to the rear spacer panel  135  by connecting device  131 . The rear spacer panel  135  is connected generally perpendicular to the rear end of the top panel  105 . The rear panel  130  is also shown in its fully folded position. Since the front panel  140  is connected directly to the top panel  105 , when it is in its fully folded position, it lays generally flush to the interior of the top panel  105 . This flush orientation is desirable in order to minimize the space that the structure  100  uses when in transport. In fact, this type of flush orientation is desirable for all of the remaining panels  110 ,  115 ,  130 . As such, since the rear panel  130  is the next panel that is folded, the rear spacer panel  135  provides a spacing from the top panel  105  to the connection device  131  that is generally equal to the thickness of the front panel  140 . As such, the width W Rear  of the rear spacer panel  135  is generally equal to the thickness T Front  of the front panel  140 . It is appreciated that if W Rear  is less than T Front , then the rear panel  130  would not lie flush on the front panel  140 . Similarly, if W Rear , is greater than T Front , then the rear panel  130  would also not lie flush on the front panel  140 . It is further understood that small variances between W Rear  and T Front  can be expected in actual practice. 
   Arrows C, D are shown as are illustrated in  FIGS. 6 and 7  above. The side panels  110 ,  115  are also shown in  FIG. 12 . The side spacer panel  120  is further illustrated. The dimensional relationship and spatial orientations of the side panels  110 ,  115  with respect to the front and rear panels  140 ,  130  as well as the entire structure  100  are now described. 
     FIG. 13  illustrates a front view of an embodiment of a folding modular structure  100 . The structure  100  is illustrated in its fully folded position. The front panel  140  is pivotally connected to the top panel  105  by pivoting devices  141 . The rear spacer panel  135  is connected generally perpendicular to the top panel  105  and the rear panel  130  is pivotally connected to the rear spacer panel  135  by pivoting device  131  as described above. Also as described above, it is desirable that all remaining side panels  110 ,  115  also lie flush upon one another and the front and rear panels  140 ,  130 . As such, the side spacer panels  120 ,  125 , which are connected generally perpendicular to the top panel  105 , also have certain dimensional and spatial relationships. 
   The side spacer panel  120  generally has the greatest width of all of the spacer panels described herein. In general, in order for the remaining panels to lie flush, the width W Side1  of the side panel  120  is generally equal to the thickness of the front panel T Front  plus the thickness of the rear panel T Rear  plus the thickness of the side panel  125  T Side2 . Furthermore, the width W Side2  of the side spacer panel  125  is generally equal to the thickness of the front panel T Front  plus the thickness of the rear panel T Rear . As a general rule, in order for the panels to fit flush, each spacer panel connected to the panel being currently folded generally has a width equal to the sum of the thicknesses of the panels already folded under. As such, it is appreciated that the front panel  140  has no spacer panel since there are no panels folded underneath. Similarly, the remaining spacer panels have widths equal to the sum of the thicknesses of the folded panels as described in detail above. It is also appreciated that the longest panel from the base onto which the structure  100  stands to the top panel  105  is the front panel  140 . The next longest panel is the rear panel  130  that is shorter than the front panel  140  by the width W Rear  of the rear spacer panel  135 . The next longest panel is the side panel  115  that is shorter than the front panel  140  by the width W Side2  of the side spacer panel  125 . The shortest panel is the side panel  120  which is shorter than the front panel  140  by the width W Side1  of the side spacer panel  120 . It is also appreciated that the overall widths of the panels can be described relative to one another and not just the front panel  140 . 
   It is appreciated that the structure  100  may have panels of varying thicknesses. If the structure  100  included panels all having the same thickness T, then the general rule could be that the rear spacer panel  135  has width equal to T, the side spacer panel has width equal to 2T and the side spacer panel  120  has the width 3T. Once again, it is understood that there are variances in the widths and thicknesses that may vary the general rules. Furthermore, it may be desired to leave small spaces between the panels therefore requiring that the widths of the spacer panels may be larger than described above. 
   It is further appreciated that a certain order of folding and unfolding has been described above. It is understood that other folding and unfolding orders are contemplated. For example, the rear panel  130  may not include a spacer panel and the front panel may include a spacer panel so that the front panel  140  folds out first and the rear panel  130  folds out last. The same may be true for the side panels  110 ,  115 . The side panel  110  may not include a spacer panel so that it folds out last. As such the side panel  115  and the front and rear panels  140 ,  130  would include increasingly wide spacer panels as described above for the side panels  110 ,  115 . Therefore, it is understood that there can be many variances in the widths of the spacer panels and the folding orders of the panels so long as the general rule that the spacer panel is generally as wide as the panels that have already been folded in order to keep the panels generally flush with one another. 
   The embodiments described above have discussed the general structure  100  that is foldable for easy transport and deployment. This structure  100  can have a variety of uses where structures are required. For example, several remote structures are often required for meteorological and cellular tower stations, which can be difficult to deploy, due to remote locations and narrow access roads. By the structure  100  being foldable, the structure can more easily be transported to these remote locations. It is understood that there are a variety of other uses for the structure such as, but not limited to living quarters storage facilities and the like. Furthermore, the modular nature of the structure  100  allows several of the structures  100  to be interconnected and stacked, as needed, for uses to build homes or other dwellings. 
   In a typical implementation, the structures  100  can be set side by side and stacked in order to develop jail cells or other detention facilities. As such, the structures  100  must be sturdy and meet certain requirements as appreciated by those skilled in the art. 
     FIG. 14  illustrates a top view of two-embodiments of a folding modular structure  100  placed side by side and  FIG. 15  illustrates a front view of two embodiments of a folding modular structure  100  placed side by side. The partial cut away view in  FIG. 14  illustrates that the structure  100  can include, among other things necessary for a detention cell, reinforcement beams  111  within the panels  110 ,  115 . Other reinforcement beams can also be located in the front and rear panels  140 ,  130 . The structure  100  can also include a window  142  and door  143 , which can be pre-installed on the panels as needed. Other furnishings such as plumbing, lighting and other electrical hook ups are installed. 
   As described above, to erect the structure  100 , the folded structure  100  is lifted vertically upward, inverted, and allowing the panels to unfold at their pivoting locations. As the top panel  105  is raised. Once the panels are unfolded to the vertical position, the structure  100  is placed in “jig” on the floor slab, adjusted for square and plumb, then the specially designed brackets  150  (and other hardware) are fastened in place to render the entire structure  100  rigid and structurally stable. Interior trim hardware is then installed around the inner corners where the panels meet the top panel in order to permanently conceal the pivoting devices and other folding mechanisms, and to provide additional structural stability. For a typical detention center cell, certain security grade features are also installed as well as having bullet resistance hardware. Any final painting, inspection and the like can be later performed. 
     FIG. 16  illustrates a partial cut-away top view of interconnection hardware. As described above, the structures  100  can be laid side by side on a slab  190 . This view shows tow of the structures  100  side by side illustrating the inner reinforcement beams  111 . As described above, outer brackets  150  can be secured on the lower corners  106 ,  107 ,  108 ,  109  of the structures  100  in order to secure the panels  110 ,  115 ,  130 ,  140  from pivoting. Inner brackets  182  and bolts  181  can also be secured to the structures in order to keep the panels  110 ,  115 ,  130 ,  140  from pivoting as well as securing the structures  100  to each other. Retaining bolts  180  can be used to connect the overall structures  100  to the slab  190 . It is understood that there are many variations that can be used to secure the structures  100 . 
   By way of example, in the specific implementation of a jail cell, when in the fully folded position, the structure  100  can become a unit that is “Cell Width” wide×“Cell Length” long approximately 4×“Cell Wall Thickness”+“Cell RoofDeck Thickness” high. In a more specific example, a cell that is approximately 8′0″ wide×12′0″ long×8′0″ high can be folded into a unit that is 8′0″ wide×12′0″ long by 1′0″ high (4×2″ wall thickness+4″ roof deck thickness). 
   The foregoing is considered as illustrative only of the principles of the invention. Further, various modifications may be made of the invention without departing from the scope thereof and it is desired, therefore, that only such limitations shall be placed thereon as are imposed by the prior art and which are set forth in the appended claims.

Technology Classification (CPC): 4