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.
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.
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.
An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in
Enclosure components 155 (wall component 200, floor component 300 and roof component 400) can be fabricated and dimensioned as described herein and positioned together to form a shipping module 100, shown end-on in
The enclosure components 155 of the present invention include a number of shared design features that are described below.
A. Laminate Structure Design
Enclosure components 155 can be fabricated using a multi-layered, laminate design. A particular laminate design that can be used to fabricate enclosure components 155 comprises a first structural layer 210, a foam panel layer 213, a second structural layer 215 and a protective layer 218, as shown in
In particular, first structural layer 210 is provided in the embodiment of enclosure component 155 that is depicted in
Referring again to
In the embodiment of the enclosure component 155 depicted in
In the embodiment of the enclosure component 155 depicted in
Other embodiments of multi-layered, laminate designs, which can be used to fabricate the enclosure components 155 of 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 component 155 (i.e., the edges that define the perimeter of enclosure component 155) 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 layer 213 that would otherwise be exposed at the exterior edges of enclosure components 155. 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 component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.
C. Enclosure Component Partitioning
Enclosure components 155 in certain instances are partitioned into enclosure component portions to facilitate forming a compact shipping module 100. In those instances where an enclosure component 155 is 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 module 100.
D. Enclosure Component Interior Edge Reinforcement
An enclosure component 155 partitioned 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 layer 213 which that would otherwise be exposed at the interior edges of enclosure components 155. 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 component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.
E. Enclosure Component Load Transfer
In the case of enclosure components 155, 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 components 155 that are horizontally oriented when in use (floor component 300 and roof component 400), 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 component 200), 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 in
F. Enclosure Component Sealing Systems
Structure 150 comprises 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 structure 150.
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 in
Further design details of wall component 200, floor component 300, and roof component 400 are provided in the sections following.
Typically, a structure 150 will utilize four wall components 200, with each wall component 200 corresponding to an entire wall of structure 150.
A. General Description
Wall component 200 has a generally rectangular perimeter. As shown in
As indicated above, wall components 200 of the present inventions can utilize a multi-layered, laminate design. In the embodiment depicted in
The perimeter of each wall component 200 is generally provided with exterior edge reinforcement. As exemplified by wall component 200 shown in
B. Partitioned Wall Components
Referring to
Referring again to
Notably, first wall portion 200s-1 is longer than third wall portion 200s-3 by a distance approximately equal to the thickness of wall component 200, and second wall portion 200s-2 is shorter than third wall portion 200s-3 by a distance approximately equal to the thickness of wall component 200. Furthermore, wall portion 200s-1 and wall portion 200s-3 are each shorter in length (the dimension in the transverse direction) than the dimension of floor portion 300a in the transverse direction. Dimensioning the lengths of wall portions 200s-1, 200s-2, 200s-3 and 200s-4 in this manner permits wall portions 200s-2 and 200s-4 to nest against each other in an overlapping relationship when in an inwardly folded position. In this regard,
The hinge structures referenced above, for securing first wall portion 200s-1 to second wall portion 200s-2, and third wall portion 200s-3 to fourth wall portion 200s-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.
C. Unpartitioned Wall Components
As compared to the two wall components 200 proximate first and second transverse edges 108 and 110, which are partitioned into wall portions, the remaining two wall components 200 proximate first and second longitudinal edges 106 and 116 do not comprise plural wall portions, but rather each is a single piece structure. However, one of these wall components 200, which is sometimes denominated 200P in this disclosure, and which is located on floor portion 300b proximate first longitudinal edge 106, is pivotally secured to floor portion 300b by means of hinge structures to permit wall component 200P to pivot about horizontal axis 105 shown in
The hinge structures referenced above, for securing wall component 200P to floor portion 300b, 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.
Typically, a structure 150 will utilize one floor component 300; thus floor component 300 generally is the full floor of structure 150.
A. General Description
Floor component 300 has a generally rectangular perimeter.
The length and width of floor component 300 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in
Floor component 300 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which floor component 300 may be subject. It is preferred that floor component 300 utilize a multi-layered, laminate design, such as that described in connection with
The perimeter of each floor component 300 is generally provided with exterior edge reinforcement. As exterior edge reinforcement for the embodiments of floor component 300 shown in
B. Floor Partitioning
The floor component 300 is partitioned into floor portion 300a and floor portion 300b.
Each of the floor portions 300a and 300b is a planar generally rectangular structure, with floor portion 300a adjoining floor portion 300b. Interior edge 301a of floor portion 300a abuts interior edge 301b of floor portion 300b, as shown in
Referring to structure 150 shown in
C. Hinged Vertical Load Transfer Components
Hinge Assembly 329A. Hinge assembly 329A comprises two identical hinge assembly portions 330A partnered together to form a pivoted junction. The inter-positioning of the parts of two partnered hinge assembly portions 330A is described below, and can also be seen in
Hinge assembly portion 330A, shown in
Hinge section 332 shown in
Pin interlock section 334 shown in
Free interlock section 338 shown in
Locking pin barrel 340 shown in
As can be seen in
As shown in
As can be appreciated, when hinge assembly 329A 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 barrel 340 positioned over a set of interleaved leaves 336, 339. The hinge assembly 329A is accordingly locked into the hinge closed position by inserting a locking pin 349 into the locking pin bore 341 provided in the locking pin barrel 340 of each of its two hinge assembly portions 330A, as shown in
Locking pin 349, which is shown in
To facilitate the rotation of hinge assembly 329A so that beam assembly 325 can smoothly move into the beam unfolded position shown in
A stop 324 is optionally provided at the edge of the lower free interlock leaf 339 of each hinge portion 330A of hinge assembly 329A to assist in preventing hyper-extending beam assembly 325 when unfolded. In the case where hinge assembly 329A is fabricated as a single casting, stops 324 of the partnered hinge portions 330A of each hinge assembly 329A can be more precisely machined or ground down as necessary following the casting step to insure that when hinge assembly 329A is in the hinge closed position, I-beams 326a and 326B do not extend beyond the desired beam unfolded position. In the beam unfolded position (when hinge assembly 329A is in the hinge closed position), while I-beams 326a and 326b can be co-linear, it is preferred that I-beams 326a and 326b not be co-linear. In particular, in the beam unfolded position it is preferred that hinge assembly 329A, when joined to I-beams 326a and 326b, causes those I-beams to assume a small upwardly arched configuration. This can be realized for example by designing hinge assembly portion 330A so that when hinge assembly portion 330A is secured to an end of an I-beam 326a or 326b, obverse face 318 is canted a select positive angle (i.e., angularly rotated clockwise about the centerline of hinge pin holes 327 shown in
The reverse face 319 of hinge assembly portion 330A is adapted to be secured to an end of one of I-beams 326a and 326b. The hinge assembly portions 330A that join I-beam 326a and I-beam 326b are secured to I-beams 326a, 326b with their hinge sections 332 oriented upwardly, so that I-beam 326b shown in
In the embodiment of floor component 300 shown in the figures, I-beam assembly 325 is located at the mid-point between first transverse floor edge 120 and second transverse floor edge 118, and no hinge assemblies 329A are utilized elsewhere within floor component 300, such as proximate to first transverse floor edge 120 and second transverse floor edge 118. Therefore, to assist in smoothly rotating floor portion 300b, there is provided adjacent first transverse floor edge 120 a first floor end hinge assembly 345A joining floor portions 300a and 300b, and there is provided adjacent second transverse floor edge 118 a second floor end hinge assembly 345A joining floor portions 300a and 300b. The locations of both first and second floor end hinge assemblies 345A is indicated in
Floor end hinge assembly 345A. Floor end hinge assembly 345A comprises two identical floor end hinge portions 350A. Referring to
As can be seen in
Floor end hinge portion 350 additionally includes two opposed block-out shields 355a and 355b. Block out shield 355a is positioned adjacent a first vertical edge of base plate 351 and extends away from base plate 351 in a perpendicular direction. Block out shield 355b is positioned proximate to an opposing second vertical edge of base plate 351, but is inset an inset distance 356 equal to at least the thickness of block out shield 355a, and extends away from base plate 351 in a perpendicular direction.
Referring to the floor end hinge assembly 345A shown in
Optionally, an I-beam cover 505, shown in
Typically, a structure 150 will utilize one roof component 400; thus roof component 400 generally is the full roof of structure 150.
A. General Description
Roof component 400 has a generally rectangular perimeter.
The length and width of roof component 400 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in
Roof component 400 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which roof component 400 may be subject. It is preferred that roof component 400 utilize a multi-layered, laminate design, such as that described in connection with
The perimeter of roof component 400 is generally provided with exterior edge reinforcement. As exterior edge reinforcement for the embodiment of roof component 400 shown in
B. Roof Partitioning
The roof component 400 of structure 150 is partitioned into roof portions 400a, 400b and 400c.
Each of the roof portions 400a, 400b and 400c is a planar generally rectangular structure, with roof portion 400a adjoining roof portion 400b, and roof portion 400b adjoining roof portion 400c. Interior edge 412c of roof component 400c abuts a first interior edge 412b of roof component 400b, as shown in
Referring to structure 150 shown in
In turn, roof portion 400b is joined to roof portion 400c with hinge structures provided between first interior edge 412b of roof portion 400b and interior edge 412c of roof portion 400c. Such hinge structures are adapted to permit roof portion 400c to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405b, located proximate the bottom of roof component 400 and shown in
C. Hinged Vertical Load Transfer Components
Hinge assemblies 429B and 429C are described further below.
Hinge Assembly 429B. Hinge assembly 429B comprises two identical hinge assembly portions 430B partnered together to form a pivoted junction. The inter-positioning of the parts of the two partnered hinge assembly portions 430B forming hinge assembly 429B is substantively the same as illustrated in
Hinge assembly portion 430B is shown in
Hinge section 432 shown in
Pin interlock section 434 shown in
Free interlock section 438 shown in
Locking pin barrel 440 shown in
As can be seen in
As shown in
As can be appreciated, when hinge assembly 429B 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 barrel 440 positioned over a set of interleaved leaves 436, 439. The hinge assembly 429 is accordingly locked into the hinge closed position by inserting a locking pin 349 (the same as used to lock partnered hinge assembly portions 330A in the hinge closed position, and as shown in
Locking pin 349 has a length sufficient to be received in the lock pin holes 447 of the interleaved leaves of 436, 439 positioned below it and thus lock beam assembly 425 in the beam unfolded position. As described above, it is preferable for locking pin 349 to be cylindrical in cross-section. Also as described above, locking pin 349 can be tapered along its length, so that the widest cross section is at the upper face of locking pin barrel 440. In that case, the diameter of locking pin bore 441 can be tapered, and the diameters of lock pin holes 447 in leaves 436, 439 can be correspondingly reduced, the further they are located from locking pin barrel 440. Alternatively, and as shown in
To facilitate the rotation of hinge assembly 429B so that beam assembly 425 can smoothly move into the fully unfolded position shown in
A stop 424 is optionally provided at the edge of the lower free interlock leaf 439 of each hinge portion 430B of hinge assembly 429B to assist in preventing hyper-extending beam assembly 425 when unfolded. In the case where hinge assembly 429B is fabricated as a single casting, stops 424 of the partnered hinge portions 430B of each hinge assembly 429B can be more precisely machined or ground down as necessary following the casting step to insure that when hinge assembly 429B is in the hinge closed position, I-beams 426a and 426b do not extend beyond the desired beam unfolded position. In the beam unfolded position (when hinge assembly 429B is in the hinge closed position), while I-beams 426a and 426b can be co-linear, it is preferred that I-beams 426a and 426b not be co-linear. In particular, in the beam unfolded position it is preferred that hinge assembly 429B, when joined to I-beams 426a and 426b, causes those I-beams to assume a small upwardly arched configuration. This configuration can be realized for example by designing hinge assembly portion 430B so that when hinge assembly portion 430B is secured to an end of an I-beam 426a or 426b, obverse face 418 is canted a select positive angle (i.e., angularly rotated clockwise about hinge pin hole 427 in
The reverse face 419 of hinge assembly portion 430B is adapted to be secured to an end of one of I-beams 426a and 426b. The hinge assembly portions 430B that join I-beam 426a and I-beam 426b are secured to I-beams 426a, 426b with their hinge sections 432 oriented upwardly, so that I-beam 426b shown in
Hinge Assembly 429C. Hinge assembly 429C comprises two identical hinge assembly portions 430C partnered together to form a pivoted junction. The inter-positioning of the parts of the two partnered hinge assembly portions 430C forming hinge assembly 429C is substantively the same as illustrated in
Hinge assembly portion 430C is shown in
The first exception is that the lower pin interlock leaf 436 of the hinge assembly portion 430C is extended toward free interlock section 438 to provide a platform tab 407, which is shown in
The second exception is shown in
The third exception relates to the fact that hinge assemblies 429B and 429C are mounted in opposite orientations. Referring to hinge assembly 429B, the reverse face 419 of each of its two hinge assembly portions 430B is adapted to be secured to a respective end of the two I-beams 426a and 426b adjacent to each other, and referring to hinge assembly 429C the reverse face 419 of each of the two hinge assembly portions 430C is adapted to be secured to a respective end of the two I-beams 426b and 426c adjacent to each other. As was discussed above, the hinge assembly portions 430B that join I-beam 426a and I-beam 426b are secured to those I-beams 426a, 426b with their hinge sections 332 oriented upwardly, so that I-beam 426b shown in
Similar to the beam unfolded position of I-beams 426a and 426b, while I-beams 426b and 426c can be co-linear in their beam unfolded position (when hinge assembly 429C is in the hinge closed position), it is preferred that I-beams 426b and 426c not be co-linear in that beam unfolded position. In particular, in the beam unfolded position it is preferred that hinge assembly 429C, when joined to I-beams 426b and 426c, causes those I-beams to assume a small upwardly arched configuration. This can be realized for example by designing hinge assembly portion 430C so that when hinge assembly portion 430C is secured to an end of an I-beam 426b or 426c, obverse face 418 is canted in the opposite direction as preferably found in hinge assembly 430B; in other words, it is preferred that obverse face 418 of hinge assembly portion 430C be canted a select negative angle (i.e., angularly rotated counterclockwise about hinge pin hole 427 in
In the embodiment of roof component 400 shown in the figures, I-beam assembly 425 is located at the mid-point between first transverse roof edge 408 and second transverse roof edge 410, and no hinge assemblies 429B or 429C are utilized elsewhere within roof component 400, such as proximate to first transverse roof edge 408 or second transverse roof edge 410. Therefore, to assist in smoothly rotating roof portion 400b relative to roof portion 400a, there is provided adjacent first transverse roof edge 408 a first roof end hinge assembly 445B joining roof portions 400a and 400b, and there is provided adjacent second transverse roof edge 410 a second roof end hinge assembly 445B joining roof portions 400a and 400b. Additionally, to assist in smoothly rotating roof portion 400c relative to roof portion 400b, there is provided adjacent first transverse roof edge 408 a first roof end hinge assembly 445C joining roof portions 400b and 400c, and there is provided adjacent second transverse roof edge 410 a second roof end hinge assembly 445C joining roof portions 400b and 400c. The locations of first and second roof end hinge assemblies 445B are indicated in
Roof End Hinge assembly 445B. Roof end hinge assembly 445B comprises two identical roof end hinge portions 450B. Referring to
As depicted in
Roof end hinge portion 450B additionally includes two opposed block-out shields 455a and 455b, which are shown in
The roof end hinge assemblies 445B shown in
Roof End Hinge assembly 445C. Roof end hinge assembly 445C comprises two identical roof end hinge portions 450C, one of which is shown in
The roof end hinge assemblies 445C shown in
Optionally, an I-beam cover 505, as shown in
For enclosure components 155 having the construction disclosed herein in reference to
Particular edge structure designs for metal sheets 206 and 217 are 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.
Conveyor table 50 is provided with a plurality of cylindrical rollers to facilitate movement of work pieces from the assembly area 56 into the press table 51. The enclosure components 155 are built up, layer upon layer, in the assembly area 56, and then moved into the press table 51. Press table 51 preferably employs a vacuum bag system to press together the layers forming enclosure components 155. Spray gantry 55 is movable over conveyor table 50 between a first position proximate to press table 51 and a second position distal from press table 51. Spray gantry 55 is 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 facility 10 depicted in
Additional information concerning the facility 10 shown in
It is preferred that there be a specific dimensional relationship among enclosure components 155. In reference to the embodiment shown in the figures, it is preferred that the height “H” of wall components 200 be the same as the span “Sf” between the I-beam assembly 325 of floor component 300 and either its first transverse floor edge 120 or its second transverse floor edge 118, with I-beam assembly 325 being located at the middle of floor component 300. Correspondingly, it is preferred that the height of wall components 200 be the same as the span “Sr” between the I-beam assembly 425 of roof component 400 and either its first transverse roof edge 408 or its second transverse roof edge 410, with I-beam assembly 425 being located at the middle of roof component 400. Thus it is preferred that H=Sf=Sr. Accordingly, Sf and Sr are referred to herein simply as “S”, the panel section span.
Making H=S improves the production throughput of manufacturing facility 10. Specifically, manufacturing facility 10 can be tasked with making multiple laminate panel sections sharing a common dimension based upon the bed width 49 of conveyor table 50 shown in
These same height/span relationships can also be utilized to make structures 150 where two of its opposing wall components 200 are longer than the other two opposing wall components 200. For example,
Roof portions 400a, 400b and 400c each can be identically dimensioned in the transverse direction. Alternatively, referring to
In
The shipping module 100 shown edge-on in
Sizing the enclosure components 155 of structure 150 according to the dimensional relationships disclosed above yields a compact shipping module 100, as can be seen from the figures. Thus shipping module 100 depicted in
It is preferred that the fixed space portion 102 be 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 in
Each of the wall, floor and roof components 200, 300 and 400, and/or the portions thereof, can be sheathed in protective film 177 during fabrication and prior to forming the shipping module 100. Alternatively or in addition, the entire shipping module 100 can be sheathed in a protective film. Such protective films can remain in place until after the shipping module 100 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.
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 column 3, line 26 to column 6, line 25 and in
At the building site, shipping module 100 is 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 module 100 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 100, then moving the transport means from the desired location, and then lowering shipping module 100 to a rest state at the desired location. Particularly suitable equipment and techniques for facilitating the positioning of a shipping module 100 at 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 with
Following positioning of shipping module 100 at the building site, the appropriate portions of wall, floor and roof components 200, 300 and 400 are “unfolded” (i.e., deployed) to yield structure 150. Unfolding occurs in the following sequence: (1) floor portion 300b is pivotally rotated about horizontal axis 305 (shown in
A mobile crane can be used to assist in the deployment of certain of the enclosure components 155, specifically roof portions 400b and 400c, floor portion 300b, as well as the wall component 200P pivotally secured to floor portion 300b. Alternatively, particularly suitable equipment and techniques for facilitating the deployment of enclosure components 155 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 00132-00145 and depicted in
After unfolding, the enclosure components 155 are secured together to finish the structure 150 that is shown in
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.
This application is a continuation application of PCT Patent Application No. PCT/US21/59440, filed Nov. 16, 2021, which claims the benefit of U.S. Provisional Application No. 63/136,268 filed Jan. 12, 2021 and U.S. Provisional Application No. 63/188,101 filed May 13, 2021; and this application claims the benefit of U.S. Provisional Application No. 63/136,268 filed Jan. 12, 2021 and U.S. Provisional Application No. 63/188,101 filed May 13, 2021.
Number | Date | Country | |
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63188101 | May 2021 | US | |
63136268 | Jan 2021 | US | |
63188101 | May 2021 | US | |
63136268 | Jan 2021 | US |
Number | Date | Country | |
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Parent | PCT/US2021/059440 | Nov 2021 | US |
Child | 17527520 | US |