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WO2024015355A1 - Panneau universel - Google Patents

Panneau universel Download PDF

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Publication number
WO2024015355A1
WO2024015355A1 PCT/US2023/027363 US2023027363W WO2024015355A1 WO 2024015355 A1 WO2024015355 A1 WO 2024015355A1 US 2023027363 W US2023027363 W US 2023027363W WO 2024015355 A1 WO2024015355 A1 WO 2024015355A1
Authority
WO
WIPO (PCT)
Prior art keywords
spline
foam
edge
face
structural
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2023/027363
Other languages
English (en)
Inventor
Paolo Tiramani
Galiano TIRAMANI
Kyle DENMAN
Alexander Bluhm
William SCHLECHTER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Boxabl Inc
Original Assignee
Boxabl Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Boxabl Inc filed Critical Boxabl Inc
Publication of WO2024015355A1 publication Critical patent/WO2024015355A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/001—Mechanical features of panels
    • E04C2002/004—Panels with profiled edges, e.g. stepped, serrated
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2002/3488—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by frame like structures

Definitions

  • 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.
  • stick-built construction 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.
  • Boxabl® foldable transportable dwelling unit which consists of a number of enclosure components (four wall components, a floor component and a roof component), and portions thereof, which are dimensioned, positioned and folded together to form a compact shipping module 15, as shown in FIG. 1A.
  • the enclosure components and enclosure component portions are dimensioned so that the shipping module 15 is within applicable highway dimensional restrictions.
  • shipping module 15 can be transported over a limited access highway more easily, and with appropriate trailering equipment, transported without the need for oversize load permits.
  • structure 150 can be manufactured in a factory, positioned and joined together to form the shipping module 15, and the modules 15 can then be transported to the desired site for the structure, where they can be readily deployed (unfolded) to yield a relatively finished structure 150, which is shown in FIG. IB.
  • factory manufacturing also has the potential to reduce manufacturing costs. For example, manufacturing improvements can advantageously reduce both assembly time and labor costs.
  • manufacturing improvements can advantageously reduce both assembly time and labor costs.
  • traditional home construction utilizes a great number of parts of different types. To capitalize on the efficiency of factory manufacturing, it is therefore desirable to reduce the variety of parts needed for dwelling assembly.
  • the present invention constitutes an advancement in enclosure component design that reduces the number of core elements needed to manufacture the floor, roof and wall components of a dwelling unit.
  • the present invention is directed to an enclosure component for a building structure, where the enclosure component comprises a first structural layer, a core layer and a second structural layer.
  • the first structural layer has a first face, an opposed second face and comprises a first structural panel of magnesium oxide arranged in a side-by- side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline arranged in a side-by-side relationship with a second structural panel of magnesium oxide.
  • the core layer has a first face, an opposed second face and comprises a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, with a second edge of the foam spline opposed to the first edge of the foam spline arranged in a side-by-side relationship with a second foam panel, and with the first face of the core layer bonded to the second face of the first structural layer.
  • a first lap joint spline of magnesium oxide is positioned between the first extension spline of the first structural layer and the first face of the core layer, and joins the first and second structural panels of the first structural layer.
  • the second structural layer has a first face, an opposed second face and comprises a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, and with the second face of the core layer bonded to the first face of the second structural layer.
  • a second lap joint spline of magnesium oxide is positioned between the second extension spline of the second structural layer and the second face of the core layer, and joins the first and second structural panels of the second structural layer.
  • an exemplary enclosure component for a building structure has a length, a width and a thickness.
  • the enclosure component includes a first structural layer having a first face, an opposed second face and including a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline in a side-by-side relationship with a second structural panel of magnesium oxide.
  • the enclosure component includes a core layer having a first face, an opposed second face and including a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, and with a second edge of the foam spline opposed to the first edge of the foam spline in a side-by-side relationship with a second foam panel, with the first face of the core layer bonded to the second face of the first structural layer.
  • the enclosure component includes a first lap joint spline of magnesium oxide, positioned between the first extension spline of the first structural layer and the first face of the core layer, and joining the first and second structural panels of the first structural layer.
  • the enclosure component includes a second structural layer having a first face, an opposed second face and including a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, and with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, with the second face of the core layer bonded to the first face of the second structural layer.
  • the enclosure component includes a second lap joint spline of magnesium oxide, positioned between the second extension spline of the second structural layer and the second face of the core layer, and joining the first and second structural panels of the second structural layer.
  • the second extension spline can be proximate to the foam spline in a superposed relationship.
  • the first extension spline can be distal from the foam spline.
  • a surface of the first foam panel coinciding with the first face of the core layer can include a recess to receive the first extension spline.
  • a portion of the first foam panel adjacent to the second face of the core layer and proximate to the first edge of the foam spline can define a recess to receive a first edge of the second lap joint spline
  • a portion of the second foam panel adjacent to the second face of the core layer and proximate to the second edge of the foam spline can define a second recess to receive a second edge of the second lap joint spline opposed to the first edge of the second lap joint spline.
  • the enclosure component can include a rigid beam within the foam spline, the rigid beam having a first surface that is coplanar with the second face of the core layer.
  • the enclosure component can include a channel formed within the foam spline proximate to a second surface of the rigid beam. The channel is opposed to the first surface of the rigid beam and distal from the second face of the core layer.
  • the foam spline can include a series of keys along the first edge of the foam spline and along the second edge of the foam spline.
  • the first foam panel can include slots at first and second abutting edges.
  • the second foam panel can include slots at first and second abutting edges.
  • the series of keys along the first edge of the foam spline are configured to be received by the slots at the first abutting edge of the first foam panel, and the series of keys along the second edge of the foam spline are configured to be received by the slots at the second abutting edge of the second foam panel, to mate the first foam panel and the second foam panel to opposing sides of the foam spline.
  • the foam spline can include a rigid beam disposed therein and extending a length of the foam spline.
  • the foam spline can include a channel disposed adjacent to the rigid beam and extending the length of the foam spline.
  • the first lap joint spline can be positioned under the first extension spline.
  • the first lap joint spline can define a width dimensioned greater than a width of the first extension spline.
  • the first lap joint spline can underlie the first extension spline and at least a portion of each of the first structural panel and the second structural panel.
  • the first face of the core layer can include a recess formed therein, the recess dimensioned equally to a thickness of the first lap joint spline to receive the first lap joint spline such that the second face of the first structural layer lies flat against the first face of the core layer.
  • the first structural layer is disposed against the first face of the core layer and the second structural layer is disposed against the second face of the core layer.
  • a position of the first lap joint spline at the first face of the core layer is offset a distance along the core layer from a position of the second lap joint spline at the second face of the core layer.
  • Seams of the first lap joint spline with the first structural layer do not match to corresponding seams of the second lap joint spline with the second structural layer across a thickness of the core layer due to the offset. Seams of the first structural layer do not match to corresponding seams of the second structural layer across a thickness of the core layer.
  • FIG. 1A is a perspective view of a folded building structure (a shipping module)
  • FIG. IB is a perspective view of an unfolded building structure.
  • FIG. 2 is a top schematic view of the structure shown in FIG. IB.
  • FIG. 3 is an end view of a shipping module as shown in FIG. 1A, from which is formed the structure shown in FIG. IB.
  • FIG. 4 is an exploded perspective view of the panel of the present invention.
  • FIG. 5 is an exploded side view of the panel of the present invention.
  • FIG. 6 is a side view of the panel of the present invention showing certain details of the foam spline and lap joint spline of the present invention.
  • FIGS. 1-3 An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in FIGS. 1-3.
  • structure 150 When fully unfolded, as exemplified by FIG. IB, structure 150 has a rectangular shape made of three types of generally planar and rectangular enclosure components 155, the three types of enclosure components 155 consisting of a wall component 200, a floor component 300, and a roof component 400.
  • the perimeter of structure 150 is defined by first longitudinal edge 106, first transverse edge 108, second longitudinal edge 116 and second transverse edge 110.
  • first longitudinal edge 106 and second longitudinal edge 116 may be referred to as the “longitudinal” direction
  • a direction parallel to first transverse edge 108 and second transverse edge 110 may be referred to as the “transverse” direction
  • a direction parallel to the vertical direction in FIG. IB may be referred to as the “vertical” direction.
  • Structure 150 as shown has one floor component 300, one roof component 400 and four wall components 200; although it should be understood that the present inventions are applicable to structures having other configurations as well.
  • 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 single universal panel 165, which is characterized by a series of repeating elements to form an enclosure component 155 of an arbitrary size, as desired.
  • the panel 165 utilizes a multi-layered, laminate design generally shown in FIG. 4.
  • the elements of panel 165 comprise a core layer 160, a first structural layer 170 and a second structural layer 180.
  • a core unit 161 comprises a planar foam panel 163 adjoining a foam spline 164, and each core unit 161 is the same as the other core units 161; i.e., core unit 1611, core unit 1612 . . . core unit 16 l m are the same.
  • z > 2 m number of core units are arranged in a side-by-side, contacting relationship to form a core layer 160 of arbitrary length; i.e., foam panel 1631 , foam spline 164i , foam panel 1632, foam spline 1642, . . . foam panel 164 m , foam spline 164 m .
  • foam panel 1631 foam panel 1631 , foam spline 164i , foam panel 1632, foam spline 1642, . . . foam panel 164 m , foam spline 164 m .
  • foam panels 163 can be facilitated by providing a series of keys 166a along the edge of foam spline 164, shown generally in FIG. 4, which are received in corresponding slots 166b located along the abutting edge of foam panel 163.
  • Foam panels 163 can be made for example of expanded polystyrene (EPS) or polyurethane foam.
  • Each foam spline 164 has an elongate cuboid shape characterized by a foam spline length (“X” direction in FIG. 4) greater than the foam spline width (“Y” direction in FIG. 4) or the foam spline thickness (“Z” direction in FIG. 4), as shown in FIG. 4.
  • Foam splines 164 can be made of the same material as foam panels 163, such as expanded polystyrene (EPS) or polyurethane foam.
  • EPS expanded polystyrene
  • a first surface of beam 167 whose area is defined by the length and width of beam 167 is coplanar with a first surface of foam spline 164.
  • a second surface of beam 167 which is opposed to the first surface of beam 167 and is distal from the first surface of foam spline 164 (referenced above), is proximate to a channel 169, shown end-on in FIG. 6.
  • Channel 169 is formed in the interior of foam spline 164 and runs the length of foam spline 164.
  • Each beam 167 can be made for example of laminated veneer lumber.
  • a first structural unit 171 comprises a planar first structural panel 211 adjacent a planar first extension spline 212 that is coplanar with the first structural panel 211.
  • z > 2 m number of first structural units 171 are arranged in a side-by-side, contacting relationship (first structural panel 21 li, first extension spline 212i, first structural panel 2112, first extension spline 2122, . . .
  • first structural panel 21 l m first extension spline 212 m
  • first structural layer 170 first structural layer 170 of arbitrary length.
  • z > 2 is a first structural unit 171k positioned adjacent to a first structural unit 171k+i, with first structural panel 21 lk+i of first structural unit 17 lk+i positioned adjacent to first extension spline 212k of first structural unit 171k, where 0 ⁇ k ⁇ m.
  • An elongate planar first lap joint spline 213, in this case 213k, is positioned under first extension spline 212k.
  • First lap joint spline 213k has a width greater than the width of first extension spline 212k so as to underlie a narrow portion of each of first structural panel 21 lk+i and first structural panel 211k.
  • a rectangular recess 168 k+i is cut into foam panel 163k+i to receive first lap joint spline 213k and allow the portions first structural panels 21 Ik, 21 lk+i overlapping foam panel 163 k+i to lie flat against foam panel 163 k+i, as shown in FIG. 6.
  • First structural panels 211, first extension splines 212 and first lap joint splines 213 can each be made of an inorganic composition of relatively high strength, such as magnesium oxide (MgO).
  • a second structural unit 181 comprises a planar second structural panel 216 adjacent a planar second extension spline 217 that is coplanar with the second structural panel 216.
  • z > 2 m number of second structural units 181 are arranged in a side-by-side, contacting relationship (second structural panel 216i, second extension spline 217i, second structural panel 2162, second extension spline 2172, . . .
  • second structural panel 216 m second extension spline 217 m
  • second structural layer 180 of arbitrary length.
  • z > 2 is a second structural unit 181k positioned adjacent to a second structural unit 18 lk+i
  • second structural panel 216k+i of second structural unit 18 lk+i positioned adjacent to second extension spline 217k of second structural unit 181k, where 0 ⁇ k ⁇ m.
  • each foam spline 164 is oriented so that the first surface of beam 167, which is coplanar with the first surface of foam spline 164, is adjacent to second structural layer 180.
  • an elongate planar second lap joint spline 218, in this case 218k, is positioned under second extension spline 217k.
  • Second lap joint spline 218k has a width greater than the width of second extension spline 217k so as to overlap a narrow portion of each of second structural panel 216k+i and second structural panel 216k.
  • a rectangular recess edge 162 k is cut into the edge of foam panel 163k to receive a first edge region of second lap joint spline 218k
  • a rectangular recess edge 162 k+i is cut into the edge of foam panel 163k+i to receive a second edge region of second lap joint spline 218k
  • the thickness of foam spline 164 k is less than the thickness of foam panels 163 k, 163 k+i by an amount equal to the thickness of second lap joint spline 218k.
  • the kth first extension spline 212 does not overlie the corresponding kth second extension spline 218, but rather is offset a select distance so that the seams between and in each of the first structural units 171 do not match the corresponding seams between and in each of the second structural units 181 across the thickness (measured parallel to the z-axis) of panel 165.
  • the core layer 160, first structural layer 170 and second structural layer 180 of each panel 165 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive.
  • each first lap joint spline 213 underlying the narrow portion of the abutting first structural panel 211 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive
  • the portion of each second lap joint spline 218 overlapping the narrow portion of the second structural panel 216 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive.
  • each first structural panel 211 be four feet (1.22 m) wide by eight feet (2.44 m) long, and that each second structural panel 216 be four feet (1.22 m) wide by eight feet (2.44 m) long. It is further preferred that each first extension spline 212 be nine inches (0.23 m) wide by eight feet (2.44 m) long, and that each second extension spline 217 be nine inches (0.23 m) wide by eight feet (2.44 m) long. With these dimensions, each first structural unit 171, core unit 161 and second structural unit 181 will have a width of 57 inches (1.45 m).
  • 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 15.
  • 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 15.
  • 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.
  • wall component 200 floor component 300, and roof component 400 are provided in the sections following.
  • 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 FIG. IB, wall components 200 have plural apertures, specifically a door aperture 202, which has a door frame and door assembly, and plural window apertures 204, each of which has a window frame and a window assembly.
  • the height and length of wall components 200 can vary in accordance with design preference, subject as desired to the dimensional restrictions applicable to transport, described above.
  • structure 150 is fashioned with all sides of equal length; accordingly, its first and second longitudinal edges 106 and 116, and its first and second transverse edges 108 and 110, are all of equal length. It should be understood however, that the inventions described herein are applicable to structures having other dimensions, such as where two opposing wall components 200 are longer than the other two opposing wall components 200.
  • structure 150 has two opposing wall components 200, where one of the two opposing wall components 200 comprises first wall portion 200s- 1 and second wall portion 200s-2, and the other of the two opposing wall components 200 comprises third wall portion 200s-3 and fourth wall portion 200s-4.
  • Each of wall portions 200s- 1, 200s-2, 200s-3 and 200s-4 has a generally rectangular planar structure.
  • the interior vertical edge 192-1 of wall portion 200s- 1 is proximate to a respective interior vertical edge 192-2 of wall portion 200s-2
  • the interior vertical edge 194-3 of wall portion 200s-3 is proximate a respective interior vertical wall edge 194-4 of wall portion 200s-4.
  • first wall portion 200s- 1 is fixed in position on floor portion 300a proximate to first transverse edge 108
  • third wall portion 200s-3 is fixed in position on floor portion 300a, opposite first wall portion 200s- 1 and proximate to second transverse edge 110.
  • First wall portion 200s- 1 is joined to second wall portion 200s-2 with a hinge structure that permits wall portion 200s-2 to pivot about vertical axis 192 between a folded position and an unfolded position
  • third wall portion 200s-3 is joined to fourth wall portion 200s-4 with a hinge structure to permit fourth wall portion 200s-4 to pivot about vertical axis 194 between a folded position and an unfolded position.
  • 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
  • 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.
  • 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.
  • FIG. 2 depicts wall portions 200s-2 and 200s-4 both in their unfolded positions, where they are labelled 200s-2u and 200s4-u respectively, and FIG. 2 also depicts wall portions 200s-2 and 200s-4 both in their inwardly folded positions, where they are labelled 200s-2f and 200s4-f respectively.
  • wall portions 200s-2 and 200s-4 are in their inwardly folded positions (200s-2f and 200s-4f), they facilitate forming a compact shipping module.
  • wall portion 200s-2 When wall portion 200s-2 is in its unfolded position (200s-2u), it forms with wall portion 200s- 1 a wall component 200 proximate first transverse edge 108, and when wall portion 200s-4 is in its unfolded position (200s-4u), it forms with wall portion 200s-3 a wall component 200 proximate second transverse edge 110.
  • 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.
  • 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 FIG. 3 from a folded position to an unfolded position. Pivotally securing wall component 200P also facilitates forming a compact shipping module 15.
  • the remaining wall component 200 is rigidly secured on floor portion 300a proximate second longitudinal edge 116 and abutting the vertical edges of first wall portion 200s- 1 and third wall portion 200s-3 proximate to second longitudinal edge 116, as shown in FIG. 2.
  • 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 FIG. IB and 2, floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).
  • 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.
  • the floor component 300 is partitioned into floor portion 300a and floor portion 300b.
  • FIG. 2 shows flow portions 300a and 300b in plan view.
  • Each of the floor portions 300a and 300b is a planar generally rectangular structure, with floor portion 300a adjoining floor portion 300b.
  • floor portion 300a is fixed in position relative to first wall portion 200s- 1, third wall portion 200s-3 and wall component 200R.
  • Floor portion 300a is joined with hinge structures to floor portion 300b, so as to permit floor portion 300b to pivot through approximately ninety degrees (90°) of arc about a horizontal axis 305, generally located as indicated in FIG. 3, proximate the top surface of floor component 300, between a fully folded position, where floor portion 300b is vertically oriented as shown in FIG. 3, and the fully unfolded position shown in FIG. 2, where floor portion 300b is horizontally oriented and co-planar with floor portion 300a.
  • 90° ninety degrees
  • 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.
  • FIG. IB depicts roof component 400.
  • the length and width of roof component 400 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIG. IB, the length and width of roof component 400 approximates the length and width of floor component 300.
  • 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.
  • the roof component 400 of structure 150 is partitioned into roof portions 400a, 400b and 400c, shown in FIGS. 1A and 3 when folded, and in FIG. IB when unfolded.
  • 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.
  • roof portions 400a, 400b and 400c preferably are accordion folded (stacked), with roof component 400b stacked on top of roof component 400a, and roof component 400c stacked on top of the roof component 400b.
  • roof portion 400a is fixed in position relative to first wall portion 200s- 1, third wall portion 200s-3 and wall component 200R.
  • roof portion 400a is joined to roof portion 400b with hinge structures that are adapted to permit roof portion 400b to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405a (see FIG. 3) between the roof fully folded position shown in FIGS.
  • roof portion 400b lies stacked flat against roof portion 400a, and the fully unfolded position shown in FIG. IB.
  • roof portion 400b is joined to roof portion 400c with hinge structures that 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 (see FIG. 3) between the folded position shown in FIGS. 1A and 3, where roof portion 400c lies stacked flat against roof portion 400b (when roof portion 400b is positioned to lie flat against roof portion 400a), and the fully unfolded position shown in FIG. IB.
  • structure 150 includes a fixed space portion 102 defined by roof component 400a (shown in FIG. 3), floor component 300a, wall component 200R, wall portion 200s- 1 and wall portion 200s-3. (Fixed space portion 102 is also shown edge-on in the shipping module 15 depicted in FIG. 3). It is preferred that the fixed space portion 102 be fitted out during manufacture with internal components, such as kitchens, bathrooms, closets, storage areas, corridors, etc., so as to be in a relatively finished state prior to shipment of shipping module 15. Also, in the embodiment shown in FIGS. 1A, IB and 2, wall components 200 are fitted during manufacture and prior to shipment with all necessary door and window assemblies, with the enclosure components 155 being pre-wired for electrical needs. [0058] 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 15.
  • enclosure components 155 It is preferred that there be a specific dimensional relationship among enclosure components 155.
  • FIG. 2 shows a top schematic view of structure 150 shown in FIGS. 1A and IB, and includes a geometrical orthogonal grid for clarity of explaining the preferred dimensional relationships among its enclosure components 155.
  • the basic length used for dimensioning is indicated as “E” in FIG. 2; the orthogonal grid overlaid in FIG. 2 is 4E long and 4E wide; notably, the entire structure 150 preferably is bounded by this 4E by 4E orthogonal grid.
  • Roof portions 400a, 400b and 400c each can be identically dimensioned in the transverse direction.
  • roof portion 400c can be dimensioned to be larger than either of roof portion 400a and roof portion 400b in the transverse direction to reduce the chances of binding during the unfolding of roof portions 400b, 400c.
  • Further specifics on dimensioning roof portion 400c in the foregoing manner are described in U.S. Non-Provisional Application No. 17/569,962, entitled “Improved Folding Roof Component,” filed on January 6, 2022.
  • friction-reducing components can be used to facilitate unfolding roof component 400, such as by positioning a first wheel caster at the leading edge of roof portion 400c proximate to the comer of roof portion 400c that is supported by wall portion 200s-2 as roof portion 400c is deployed, and by positioning a second similar wheel caster at the leading edge of roof portion 400c proximate to the comer of roof portion 400c that is supported by wall portion 200s-4 as roof portion 400c is deployed.
  • the four wall components 200 are each approximately 4E long, and each of roof portions 400a and 400b is approximately 4E long and 1.25E wide. Roof portion 400c is approximately 4E long and 1.45E wide.
  • each of floor components 300a and 300b is 4E long; whereas floor component 300a is just over 1.5E wide and floor component 300b is just under 2.5E wide.
  • fourth wall portion 200s-4 is folded inward and positioned generally against fixed space portion 102, and second wall portion 200s-2 is folded inward and positioned generally against fourth wall portion 200s-4 (wall portions 200s-2 and 200s-4 are respectively identified in FIG. 2 as portions 200s-2f and 200s-4f when so folded and positioned).
  • roof components 400a, 400b and 400c are shown unfolded in FIG. IB and shown folded (stacked) in FIG. 3, with roof component 400b stacked on top of roof component 400a, and roof component 400c stacked on top of the roof component 400b.
  • Wall component 200P shown in FIGS. 2 and 3, is pivotally secured to floor portion 300b at the location of axis 105, and is vertically positioned against the outside of wall portions 200s-2 and 200s-4.
  • floor portion 300b is vertically positioned proximate fixed space portion 102, with wall component 200P pending from floor portion 300b between floor portion 300b and wall portions 200s-2 and 200s-4.
  • shipping module 15 depicted in FIG. 3 when dimensioned according to the relationships disclosed herein using an “E” dimension (see FIG. 2) of 57 inches (144.8 cm), and when its components are stacked and positioned as shown in FIG. 3, has an overall length of approximately 19 feet (5.79 m), an overall width of approximately 8.5 feet (2.59 meters) and an overall height of approximately 12.7 feet (3.87 meters). These overall dimensions are less than a typical shipping container.
  • Each of the wall, floor and roof components 200, 300 and 400, and/or the portions thereof, can be sheathed in protective film during fabrication and prior to forming the shipping module 15.
  • the entire shipping module 15 can be sheathed in a protective film.
  • Such protective films can remain in place until after the shipping module 15 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.
  • the shipping module 15 is shipped to the building site by appropriate transport means.
  • One such transport means is disclosed in U.S. Non-Provisional Application No. 16/143,628, filed September 27, 2018 and now U.S. Patent No. 11,007,921, issued May 18, 2021; the contents of that U.S. Non-Provisional Application No. 16/143,628, filed September 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.
  • shipping module 15 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.
  • shipping module 15 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.
  • 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 15 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 15, then moving the transport means from the desired location, and then lowering shipping module 15 to a rest state at the desired location.
  • a crane either to lift shipping module 15 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 15, then moving the transport means from the desired location, and then lowering shipping module 15 to a rest state at the desired location.
  • Particularly suitable equipment and techniques for facilitating the positioning of a shipping module 15 at the desired location are disclosed in U.S.
  • the contents of that U.S. Non-Provisional Patent Application No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on February 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.
  • the enclosure components 155 are secured together to finish the structure 150 that is shown in FIG. 1A.
  • any remaining finishing operations are performed, such as addition of roofing material, and making hook-ups to electrical, fresh water and sewer lines to complete structure 150, as relevant here.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Panels For Use In Building Construction (AREA)
  • Joining Of Building Structures In Genera (AREA)

Abstract

L'invention concerne un composant d'enceinte pour une structure de bâtiment et qui comprend un premier panneau structural agencé dans une relation côte à côte avec un premier bord d'une première cannelure d'extension, et avec un second bord de la première cannelure d'extension opposé au premier bord de la première cannelure d'extension dans une relation côte à côte avec un second panneau structural. Le composant comprend un premier panneau en mousse agencé dans une relation côte à côte avec un premier bord d'une cannelure en mousse, et avec un second bord de la cannelure en mousse opposé au premier bord de la cannelure en mousse dans une relation côte à côte avec un second panneau en mousse. Le composant comprend un premier panneau structural agencé dans une relation côte à côte avec un premier bord d'une seconde cannelure d'extension, et avec un second bord de la seconde cannelure d'extension opposé au premier bord dans une relation côte à côte avec un second panneau structural.
PCT/US2023/027363 2022-07-12 2023-07-11 Panneau universel Ceased WO2024015355A1 (fr)

Applications Claiming Priority (2)

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US202263388366P 2022-07-12 2022-07-12
US63/388,366 2022-07-12

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4671038A (en) * 1986-04-30 1987-06-09 Porter William H Roof sandwich panel juncture running with the pitch
US8844243B1 (en) * 2013-03-06 2014-09-30 Jerry GILLMAN Method of connecting structural insulated building panels through connecting splines
EP3239423A1 (fr) * 2016-04-29 2017-11-01 Zenergy AB Système d'élément de panneau de construction résistant au feu
US10494813B2 (en) * 2016-08-26 2019-12-03 Kps Global Llc System and method for affixing insulated panels
US20210025163A1 (en) * 2019-07-26 2021-01-28 Viken Ohanesian Structural Wall Panel System

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090293395A1 (en) * 2008-05-30 2009-12-03 Porter William H Structural insulated panel system including junctures
US10364572B2 (en) * 2014-08-30 2019-07-30 Innovative Building Technologies, Llc Prefabricated wall panel for utility installation
US20170145692A1 (en) * 2015-11-24 2017-05-25 Vantem Composite Technologies, Llc Finish-Ready Structural Insulating Panels
US20220220737A1 (en) * 2021-01-12 2022-07-14 Build Ip Llc Sheet/Panel Design for Enclosure Component Manufacture
US20250146276A1 (en) * 2023-11-08 2025-05-08 Dieter Roland Krohmer Structural Composite Wall and Building System

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4671038A (en) * 1986-04-30 1987-06-09 Porter William H Roof sandwich panel juncture running with the pitch
US8844243B1 (en) * 2013-03-06 2014-09-30 Jerry GILLMAN Method of connecting structural insulated building panels through connecting splines
EP3239423A1 (fr) * 2016-04-29 2017-11-01 Zenergy AB Système d'élément de panneau de construction résistant au feu
US10494813B2 (en) * 2016-08-26 2019-12-03 Kps Global Llc System and method for affixing insulated panels
US20210025163A1 (en) * 2019-07-26 2021-01-28 Viken Ohanesian Structural Wall Panel System

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