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, in an effort to reduce costs. In this regard, significant advancements in the construction of dwellings and commercial space have been made by the current inventors, as exemplified by their patent documents, including U.S. Pat. Nos. 8,474,194, 8,733,029, 10,688,906, 10,829,029, 10,926,689 and 11,220,816. In one aspect, these patents pertain to fabricating wall, floor and roof components in a factory that are folded together into a compact shipping module, and which are then transported to the intended location and unfolded to yield a fully formed structure.
The present inventions describe advancements in the design of appurtenances for building structures, particularly for the wall components of such structures.
In a first aspect, the present inventions are directed to a toe screw housing for securing abutting enclosure components together. The toe screw housing comprises a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face. There is provided a toe screw well, joined to and extending away from the interior face of the bearing plate, which includes a fastener shelf, and there is provided a toe screw support that is joined to the interior face of the toe screw housing, and which is also joined to and extending away from the fastener shelf. The toe screw support distal from the fastener shelf includes a planar support surface oriented perpendicular to the interior face. A fastener bore passes through the fastener shelf, the toe screw support and the support surface, and is inclined at a non-perpendicular second angle relative to the interior face of the bearing plate.
In a second aspect, the present inventions are directed to a baseboard for masking a toe screw bearing plate that has a beveled upper edge. The baseboard comprises a planar elongate member having an elongate interior face, an elongate top edge and an elongate bottom edge. An elongate hook ledge is joined to the top edge of the base board to form a wedge-shaped angled slot that is oriented to be open in the direction of the bottom edge, with the wedge-shaped angled slot configured to be positioned over the beveled upper edge of the bearing plate. There is provided an elongate linear first step positioned on the interior face below the angled slot to form an elongate first recess on the interior face configured to receive the toe screw bearing plate, and there is provided an elongate second step positioned on the interior face below the elongate first step to form an elongate second recess on the interior face.
These and other aspects of the present inventions are described in the drawings annexed hereto, and in the description of the preferred embodiments and claims set forth below.
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.
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 that 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 0034-57 and depicted in FIGS. 4A-4D thereof.
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 foam panel material 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.
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.
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 foam panel material 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.
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 0074-0089 and 0104-0126 and in FIGS. 8A-13E and 15A-24A thereof, as well as the description of the associated end hinge assemblies set forth for example in
0090-0093 and 0127-0132 and in FIGS. 14A-14B, 24B and 25A-25D thereof.
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 this disclosure, are incorporated by reference as if fully set forth herein, particularly including the sealing systems described for example at 0080-0167 and depicted in FIGS. 9-20 thereof, and also including the exemplary placements for such sealing systems described in
0168-0174 and depicted in FIGS. 8A-8B thereof.
Further design details of wall component 200, floor component 300, and roof component 400 are provided in the sections following.
Typically, structure 150 will utilize four wall components 200, with each wall component 200 corresponding to an entire wall of structure 150.
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
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 fourth wall portion 200s-4 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 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 hinge structures. Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material.
As compared to the two wall 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 to permit wall component 200P to pivot about horizontal axis 105 shown in
The hinge structures described 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 hinge structures. Suitable hinge structures can be fabricated for example of metal, plastic, leather, ferrous or non-ferrous material.
Certain appurtenances can be fitted to wall components 200 to facilitate fastening them to floor component 300 (described below), as well as to improve the interior appearance and speed fabrication.
As a first appurtenance that can be fitted to wall components 200,
An upper portion of semi-cylindrical wall 298 is angularly sectioned, for example at an angle of ninety degrees (90°) minus φ1, relative to axial centerline 198, for example in the range of forty-five (45°) to twenty (20°) degrees, such as thirty (30°) degrees, with the upper portion so sectioned joined to interior face 294. A lower portion of semi-cylindrical wall 298 is further sectioned parallel to axial centerline 198, with each of the resultant two axially-oriented edges joined to a respective triangular gusset 299. The two gussets 229 are spatially opposed and joined to the interior face 294 of bearing plate 292. Toe screw well 289 also includes a fastener shelf 239, visible in
The lower face of fastener shelf 239 is joined to a toe screw support 221. Toe screw support 221 comprises a semi-cylindrical solid 222 and a triangular wedge 223. Semi-cylindrical solid 222 has an axial centerline 197, shown in
Toe screw support 221 also includes a support surface 224 defined by the lower surfaces of semi-cylindrical solid 222 and wedge 223. Support surface 224 is perpendicularly oriented to the interior face 294 of bearing plate 292. A groove 199 is cut into the planar lower surface of support surface 224. Groove 199 is oriented parallel to the interior face 294 of bearing plate 292, and, in the embodiment shown in the figures, is spaced from interior face 294 a distance approximately equal to the thickness of protective layer 218.
A fastener bore 225 passes through fastener shelf 239 and toe screw support 221, with an exit orifice in support surface 224, thereby forming a passage through toe screw support 221 for a fastener, the head of which can be positioned against the upper face of fastener shelf 239. Preferably, the axial centerline of fastener bore 225 is co-linear with the axial centerline 197 of semi-cylindrical wall 222, so that the axial centerline of fastener bore 225 is not perpendicular to the exterior face 293 of bearing plate 292, but rather is oriented at angle φ2 from a line normal to the exterior face 293 of bearing plate 292.
Bevel edge 297 of toe screw housing 288 forms an angle φ3 with exterior face 293 to provide a sloped bevel surface between the end of bevel edge 297 and interior face 294 of bearing plate 292. Accordingly, angle φ3 is not perpendicular to the exterior face 293 of bearing plate 292, but rather is an acute angle, such as forty-five degrees (45°) or less, and in particular twenty degrees (20°).
As a second appurtenance that can be fitted to wall components 200,
For wall components 200 utilizing the laminate design shown in
Plural toe screw housings 288 can be utilized to fasten both partitioned and unpartitioned wall components 200 to floor component 300 (described below). For example, referring to
Plural toe screw housings 288 can also be utilized to fasten each of fixed wall component 200R, fixed wall portion 200s-1, fixed wall portion 200s-3 and pivoting wall portion 200s-2 to floor component 300. In the case of wall component 200R and fixed wall portions 200s-1 and 200s-3, the fastening operation just described can be undertaken during factory fabrication of fixed space portion 102, described further below.
In using toe screw housings 288 to fasten wall component 200P to floor section 300b, it can be seen in 0092, 0097-0101 and 0112-0120, and in connection with FIGS. 12 and 15, of that application. The contents of that PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as this disclosure, are incorporated by reference as if fully set forth herein, particularly including the wall end cap 246 and floor top plate 252 described for example at
0092, 0097-0101 and 0112-0120, and in connection with FIGS. 12 and 15, of that application.
In using toe screw housings 288 to fasten wall portions 200s-2 and 200s-4 to floor portions 300a and 300b, one or more screws 136 will also pass through sealing structures that are present at the junction of pivoting wall portion 200s-2 in its unfolded position and floor portions 300a/300b, and at the junction of pivoting wall portion 200s-4 in its unfolded position and floor portions 300a/300b. However, these sealing structures, namely wall end interlock A 262 (not shown) and floor top interlock 261 (not shown), differ from wall end cap 246 and floor top plate 252, in that they are designed to permit the lateral movement of wall portions 200s-2 and 200s-4 relative to floor portions 300a and 300b. A more detailed description of these sealing structures is set forth in PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as the present application, for example in 0136-0147 and in connection with FIG. 17 thereof. The contents of that PCT Patent Application No. PCT/US21/56415, entitled “Enclosure Component Sealing Systems,” filed on Oct. 25, 2021 and having the same inventors as this disclosure, are incorporated by reference as if fully set forth herein, particularly including the wall end interlock A 262 and floor top interlock 261 described for example at
0136-0147 and in connection with FIG. 17 thereof.
After the fasteners are driven into the toe screw housings 288, the housings can be masked from view by placing an interior baseboard 140 of an appropriate length over the toe screw housings, as shown in
In use, the hook ledge 145 of interior baseboard 140 engages the bevel edge 297 of the toe screw housings 288 positioned along the bottom of the wall component 200, which thus facilitates the rapid and accurate placement of interior baseboard 140. The interior baseboard 140 can be secured in place by providing for example hook-and-loop fasteners, or adhesive material, in the fastening recess 138 of the interior baseboard 140. Toe screw housings 288 and interior baseboard 140 can be made from aluminum, plastics and the like. It is preferred to fabricate the toe screw housing 288 and interior baseboard 140 from foamed polyvinyl chloride (PVC), particularly Celuka foamed PVC.
Typically, structure 150 will utilize one floor component 300; thus floor component 300 generally is the full floor of structure 150.
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
Above foam panel layer 213 there is provided sheet metal layer 216 of second structural layer 215, with sheet metal layer 216 being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Above sheet metal layer 216 of second structural layer 215, there are provided building panels 219 of protective layer 218, with building panels 219 being MgO board approximately 0.25 inch (6 mm) thick.
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
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 0074-0089 and in FIGS. 8A-13E thereof, as well as the description of the associated end hinge assemblies set forth for example in
0090-0093 and in FIGS. 14A-14B thereof.
Typically, structure 150 will utilize one roof component 400; thus roof component 400 generally is the full roof of structure 150.
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
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
In the shipping module 100 shown in
Particular embodiments of structural members, which also incorporate hinge structures suitable for joining roof portion 400a to roof portion 400b, and for joining roof portion 400b to roof portion 400c, are described in in U.S. Nonprovisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as this disclosure. The contents of that U.S. Nonprovisional patent application Ser. No. 17/527,520 entitled “Folding Beam Systems”, filed Nov. 16, 2021 and having the same inventors as this disclosure, is incorporated by reference as if fully set forth herein, particularly the description of the load transfer components set forth for example in 0104-0126 and in FIGS. 15A-24A thereof, as well as the description of the associated end hinge assemblies set forth for example in
0127-0132 and in FIGS. 24B and 25A-25D thereof.
For enclosure components 155 utilizing the multi-layered, laminate design 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 00187-00205 and 00212 and in FIGS. 8, 9A-9C, 23A-23J and 24A-24B thereof.
A facility suitable for the manufacture of enclosure components 155, as well as exemplary manufacturing steps, are also described in U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 19, 2021. The contents of U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 19, 2021, are incorporated by reference as if fully set forth herein, particularly including the facility suitable for manufacturing the enclosure components 155 of the present invention, as well as exemplary manufacturing steps, described for example at 00178-00186 and 00206-00222, and in FIGS. 22, 23A-23J and 24A-24B.
Referring to
For example, interior partition walls as desired can be put into fixed space portion 102 during manufacture. Referring to
As shown for example in
The open area between transverse partition wall 127 and wall portion 200s-3 in the embodiment shown in
Also, in the embodiment shown in
Carrying out the foregoing steps prior to shipment permits the builder, in effect, to erect a largely finished structure simply by “unfolding” (deploying) the positioned components of shipping module 100.
It is preferred that there be a specific dimensional relationship among enclosure components 155.
Roof portions 400a, 400b and 400c each can be identically dimensioned in the transverse direction. Alternatively, referring to
In
As shown 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
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 100 is shipped to the building site by appropriate transport means. One such transport means is disclosed in U.S. Nonprovisional application Ser. No. 16/143,628, filed Sep. 27, 2018 and now U.S. Pat. No. 11,007,921, issued May 18, 2021; the contents of that U.S. Nonprovisional application Ser. No. 16/143,628, filed Sep. 27, 2018 are incorporated by reference as if fully set forth herein, particularly as found at paragraphs 0020-0035 and in FIGS. 1A-2D thereof. As an alternative transport means, shipping module 100 can be shipped to the building site by means of a conventional truck trailer or a low bed trailer (also referred to as a lowboy trailer), and in the case of over-the-water shipments, by ship.
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, now U.S. Pat. No. 11,220,816. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at 126-128 and in connection with FIGS. 11A and 11B thereof.
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, now U.S. Pat. No. 11,220,816. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at 132-145 and depicted in FIGS. 12A-14B thereof.
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 toe screw housing for securing abutting enclosure components together, comprising:
a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face;
a toe screw well joined to and extending away from the interior face and including a fastener shelf;
a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and
a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate.
Clause 2. The toe screw housing of clause 1, further including a groove formed in the support surface oriented parallel to the interior face.
Clause 3. The toe screw housing of either of clause 1 or clause 2, wherein the second angle is in the range of forty-five degrees (45°) to seventy degrees (70°).
Clause 4. The toe screw housing of any one of clause 1, 2 or 3, where the second angle is sixty degrees (60°).
Clause 5. The toe screw housing of any one of clause 1, 2, 3 or 4, where the first angle is less than forty-five degree (45°).
Clause 6. The toe screw housing of any one of clause 1, 2, 3, 4 or 5, where the first angle is twenty degrees (20°).
Clause 7. A baseboard for masking a toe screw bearing plate having a beveled upper edge, comprising:
a planar elongate member having an elongate interior face, an elongate top edge and an elongate bottom edge;
an elongate hook ledge joined to the top edge of the base board forming a wedge-shaped angled slot that is oriented to be open in the direction of the bottom edge, the wedge-shaped angled slot configured to be positioned over the beveled upper edge of the bearing plate;
an elongate linear first step positioned on the interior face below the angled slot to form an elongate first recess on the interior face configured to receive the toe screw bearing plate; and
an elongate second step positioned on the interior face below the elongate first step to form an elongate second recess on the interior face.
Clause 8. A baseboard as in clause 7, further comprising a first elongate linear notch in the second step a first select distance above the bottom edge.
Clause 9. A baseboard as in either of clause 7 or clause 8, further comprising a second elongate linear notch in the second step a second select distance above the bottom edge that is greater than the first select distance.
Clause 10. A system for securing abutting enclosure components together, comprising:
(a) a toe screw housing that includes:
(i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face;
(ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf;
(iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and
(iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and
(b) a planar elongate base board having an elongate top edge and an elongate bottom edge and including;
(i) an elongate hook ledge joined to the top edge of the base board, the hook ledge positioned over the beveled upper edge of the bearing plate; and
(ii) an elongate linear first step positioned on the interior face below the angled slot to form an elongate first recess on the interior face in which is positioned the toe screw bearing plate.
Clause 11. The system of claim 10, further comprising (iii) an elongate second step positioned on the interior face of the base board below the elongate first step to form an elongate second recess on the interior face.
Clause 12. A wall component comprising:
(a) a foam panel layer having a first face and an opposing second face;
(b) a metal sheet layer having a first face, an opposing second face, with the first face of the metal sheet layer being bonded to the opposing second face of the foam panel layer; and
(c) a protective layer having a first face, an opposing second face, with the first face of the protective layer being bonded to the opposing second face of the sheet metal layer;
(d) an elongate external edge reinforcement abutting the foam panel layer;
(e) a plurality of toe screw housings, each of the plurality of toe screw housings comprising:
(i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face;
(ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf;
(iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and
(iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and
(f) the toe screw well and toe screw support of each toe screw housing positioned in a respective one of a plurality of spaced-apart apertures passing through the protective layer and the metal sheet layer, and in a respective one of a plurality of corresponding cavities formed in the foam panel layer, with the planar support surface of the toe screw support of each of the plurality of toe screw housings positioned against the external edge reinforcement and with the interior face of the bearing plate positioned against the protective layer
Clause 13. A folded building structure transportable to a site at which the folded building structure is to be erected, comprising:
a fixed space portion defined by (i) a first floor portion having an edge reinforcement along a first outside edge and an edge reinforcement segment along an adjacent second outside edge, (ii) a first wall component having an edge reinforcement along a first bottom edge positioned on the first floor portion proximate the first outside edge, and (iii) a planar fixed wall portion of a second wall component having an edge reinforcement segment along a second bottom edge positioned on the first floor portion proximate the second outside edge;
a second floor portion vertically positioned in a second floor portion folded position opposite to the first wall component and pivotally connected to the first floor portion to permit the second floor portion to pivot, about a first horizontal axis relative to the first floor portion, from the second floor portion folded position to a second floor portion unfolded position, the second floor portion having an edge reinforcement along a third outside edge distal from the first horizontal axis and an edge reinforcement segment along an adjacent fourth outside edge;
a third wall component vertically positioned in a third wall component folded position against the second floor portion, the third wall component pivotally connected to the second floor portion to permit the third wall portion to pivot, about a second horizontal axis relative to the second floor portion, from the third wall component folded position to a third wall component unfolded position, the third wall component having an edge reinforcement along a third bottom edge positioned on the second floor portion proximate to the third outside edge when the second floor portion is in the second floor portion unfolded position and the third wall component is in the third wall component unfolded position;
the second wall component additionally including a planar pivoting wall portion having an edge reinforcement segment along a fourth bottom edge, the pivoting wall portion (i) disposed in a pivoting portion folded position proximate the fixed space portion, and (ii) pivotally connected to the fixed wall portion of the second wall component to permit the pivoting wall portion to pivot, about a vertical axis relative to the fixed wall portion of the second wall component, from the pivoting portion folded position to a pivoting portion unfolded position in which at least a portion of the fourth bottom edge is positioned on the second floor portion proximate to the fourth outside edge when the second floor portion is in the second floor portion unfolded position and the pivoting wall portion is in the pivoting portion unfolded position;
a first plurality of toe screw housings having a spaced-apart relationship, each of the first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and
the toe screw well and toe screw support of at least a first of the first plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the pivoting wall portion and with its support surface against the edge reinforcement segment along the fourth bottom edge of the pivoting wall portion.
Clause 14. A folded building structure as in clause 13, further comprising a second plurality of toe screw housings having a spaced-apart relationship, each of the second plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and the toe screw well and toe screw support of each of the second plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the third wall component and with its support surface against the edge reinforcement along the third bottom edge of the third wall component.
Clause 15. A folded building structure as in either of clause 13 or clause 14, further comprising a third plurality of toe screw housings having a spaced-apart relationship, each of the third plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate;
the toe screw well and toe screw support of each of the third plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the first wall component and with its support surface against the edge reinforcement along the first bottom edge of the first wall component; and
a first fastener positioned within at least one of the third plurality of toe screw housings, the first fastener comprising a head in pressing contact with the fastener shelf thereof, and a shank passing through the toe screw well thereof, through the edge reinforcement along the first bottom edge of the first wall component and into the edge reinforcement along the first outside edge of the first floor portion.
Clause 16. A folded building structure as in any one of clause 13. 14 or 15, further comprising a fourth plurality of toe screw housings having a spaced-apart relationship, each of the fourth plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate;
the toe screw well and toe screw support of each of the fourth plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the fixed wall portion and with its support surface against the edge reinforcement segment along the second bottom edge of the fixed wall portion; and
a second fastener positioned within at least one of the fourth plurality of toe screw housings, the second fastener comprising a head in pressing contact with the fastener shelf thereof, and a shank passing through the toe screw well thereof, through the edge reinforcement segment along the second bottom edge of the fixed wall portion and into the edge reinforcement segment along the second outside edge of the first floor portion.
Clause 17. A building comprising:
an interior region defined by (i) a floor portion having an edge reinforcement along a first outside edge and an edge reinforcement segment along an adjacent second outside edge, (ii) a wall component having an edge reinforcement along a first bottom edge positioned on the first floor portion proximate the first outside edge, and (iii) a wall portion having an edge reinforcement segment along a second bottom edge positioned on the first floor portion proximate the second outside edge;
a first plurality of toe screw housings having a spaced-apart relationship, each of the first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending away from the fastener shelf, the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a non-perpendicular second angle relative to the interior face of the bearing plate; and
the toe screw well and toe screw support of each of the first plurality of toe screw housings positioned with the interior face of its bearing plate against an inside surface of the wall component and with its support surface against the edge reinforcement along the first bottom edge of the wall component.
Clause 18. The building of clause 17, further comprising a first interior partition wall abutting one of (i) the inside surface of the wall component and (ii) an inside surface of the wall portion, and extending perpendicularly therefrom.
Clause 19. The building of clause 18, further comprising a second interior partition wall abutting the other of the inside surface of the wall component and the inside surface of the wall portion and extending perpendicularly therefrom to form a junction with the first interior partition wall and thereby define an enclosed interior space.
Clause 20. The building of either of clause 18 or clause 19, wherein the first interior partition wall comprises:
(a) a foam panel layer having a first face and an opposing second face;
(b) a first protective layer having a first face, an opposing second face, with the first face of the first protective layer being bonded to the first face of the foam panel layer; and
(c) a second protective layer having a first face, an opposing second face, with the first face of the second protective layer being bonded to the opposing second face of the foam panel layer.
Clause 21. The building of clause 19, wherein the second interior partition wall comprises:
(a) a foam panel layer having a first face and an opposing second face;
(b) a first protective layer having a first face, an opposing second face, with the first face of the first protective layer being bonded to the first face of the foam panel layer; and
(c) a second protective layer having a first face, an opposing second face, with the first face of the second protective layer being bonded to the opposing second face of the foam panel layer.
Clause 22. The building of either of clause 19 or clause 21, wherein the enclosed interior space includes one or more of a shower enclosure, a toilet and a wash sink.
Clause 23. The building of any one of clause 19, 21 or 22, wherein a portion of the interior region outside the enclosed interior space includes one or more of a cabinet, a countertop and a cooking facility.
Clause 24. The building of any one of clauses 17-23, wherein the first wall component comprises:
(a) a foam panel layer having a first face and an opposing second face;
(b) a metal sheet layer having a first face, an opposing second face, with the first face of the metal sheet layer being bonded to the opposing second face of the foam panel layer; and
(c) a protective layer having a first face, an opposing second face that constitutes the inside surface of the first wall component, with the first face of the protective layer being bonded to the opposing second face of the sheet metal layer; and
(d) the edge reinforcement along the first bottom edge of the first wall component abuts the foam panel layer.
Clause 25. The folded building structure of clause 15, further comprising a planar elongate base board having an elongate top edge and an elongate bottom edge, with an elongate hook ledge joined to the top edge of the base board and positioned over the beveled upper edge of the bearing plate of at least one of the toe screw housings of the third plurality of toe screw housings.
Clause 26. The folded building structure of clause 16, further comprising a planar elongate base board having an elongate top edge and an elongate bottom edge, with an elongate hook ledge joined to the top edge of the base board and positioned over the beveled upper edge of the bearing plate of at least one of the toe screw housings of the fourth plurality of toe screw housings.
The foregoing detailed description is for illustration only and is not to be deemed as limiting the inventions disclosed herein, which are defined in the appended claims.
This application is a continuation in part application of PCT Patent Application No. PCT/US21/56415, filed Oct. 25, 2021, which claims the benefit of U.S. Provisional Application Nos. 63/196,400, filed Jun. 3, 2021; 63/181,447, filed Apr. 29, 2021; and 63/136,268, filed Jan. 12, 2021; and a continuation in part application of U.S. Nonprovisional application Ser. No. 17/504,883, filed Oct. 19, 2021; which claims the benefit of U.S. Provisional Application Nos. 63/196,400, filed Jun. 3, 2021; 63/181,447, filed Apr. 29, 2021; and 63/136,268, filed Jan. 12, 2021; and this application claims the benefit of U.S. Provisional Application Nos. 63/211,712, filed Jun. 17, 2021; 63/196,400, filed Jun. 3, 2021; 63/188,101, filed May 13, 2021; 63/192,349, filed May 24, 2021; and 63/181,447, filed Apr. 29, 2021.
Number | Date | Country | |
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63196400 | Jun 2021 | US | |
63181447 | Apr 2021 | US | |
63136268 | Jan 2021 | US | |
63196400 | Jun 2021 | US | |
63181447 | Apr 2021 | US | |
63136268 | Jan 2021 | US | |
63211712 | Jun 2021 | US | |
63196400 | Jun 2021 | US | |
63192349 | May 2021 | US | |
63181447 | Apr 2021 | US | |
63188101 | May 2021 | US |
Number | Date | Country | |
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Parent | PCT/US2021/056415 | Oct 2021 | US |
Child | 17587051 | US | |
Parent | 17504883 | Oct 2021 | US |
Child | PCT/US2021/056415 | US |