A process for fabricating a unitized structure comprises creating a multilayer structure by applying a flame-retardant resin to a first layer and stacking, on the first layer, an intermediate layer comprising a honeycomb structure. Further, a second layer is stacked on the intermediate layer and the flame-retardant resin is applied to the second layer. The multilayer structure is then heated to a desired temperature and a pressure is applied about the multilayer structure for a predetermined process time. Moreover, the flame-retardant resin is prevented from entering spaces of the honeycomb structure. After elapse of the predetermined process time, the pressure is released, creating the unitized structure.

An enclosure member for a building structure comprising a planar laminate having a first facing layer; a layer of foam having a first face and a second opposing face; and a second facing layer; where the first facing layer is fastened to the first face of the layer of foam, and the second facing layer is fastened to the second opposing face of the layer of foam. An edge of the enclosure is provided with a perimeter structure that can perform one or more of a sealing function, an edge reinforcement function and a pivotable joining function with another enclosure, in accordance with the particular embodiment.

Methods and systems that can produce light weight reinforced thermoplastic articles are described. In some embodiments, a method includes heating and pressing a core layer and then cooling and pressing the core layer to maintain the thickness of the core layer during cooling. Automotive articles, building articles and recreational vehicle articles that can be produced using the methods and systems are also described.

An acoustic door assembly having 1¾″ thickness, a sound transmission class (STC) rating greater than 50, UL10C 20-minute fire rating, and constructed without sheet metal or lead. In an embodiment, the door assembly includes a frame housing a decoupled internal core sandwiched between two mass-loaded vinyl outer faces. The internal core includes a multi-layering of low-density layers for absorbing high-frequency noise, damping layers of mass-loaded vinyl for absorbing low-frequency noise, and a flame-retardant layer. The outer faces are a multi-layered assembly coupled to a frame of the door assembly and in contact communication to the internal core, the outer faces having layers of mass-loaded vinyl, plywood, high-density fiberboard, and a veneer.

A foldable building structure package having a first folded configuration and a second unfolded configuration. The package has a first enclosure component portion and an enclosure member selected from the group consisting of an enclosure component and a second enclosure component portion, with the enclosure member being joined to and moveable with respect to the first enclosure component portion from a folded position to an unfolded position to form a first part of the building structure in its second unfolded configuration. There is a first deployment bracket secured to the first enclosure component portion, a deployment strut adapted to be secured to the first deployment bracket at a first end and having a rotatable sheave at a second end, and a fastener positioned on the enclosure member for receiving a line run from the tang over the rotatable sheave.

An enclosure component having a thickness for a building structure having an interior sheathing layer comprising paper; a first structural layer bonded to the interior sheathing layer and comprising a first generally rectangular structural panel of magnesium oxide arranged in a side-by-side relationship with a second generally rectangular structural panel of magnesium oxide to define a first structural panel seam between the first and second structural panels. There is a first binding strip of magnesium oxide positioned over the first structural panel seam and fastened to form a lap joint with the first structural panel and with the second structural panel, so as to bond together the first and second structural panes. The enclosure component includes a first strengthening layer, comprising woven fiber mat, bonded to the first structural layer; and a foam layer with first and second opposing faces comprising a first generally rectangular foam panel and a second generally rectangular foam panel arranged in a side-by-side relationship to define a foam panel seam between the first and second foam panels. The first structural panel seam is offset from the foam panel seam a select distance in a direction generally perpendicular to the thickness. The first strengthening layer is bonded to the first opposing face of the foam layer. The enclosure component also has a second structural layer comprising a third generally rectangular structural panel of magnesium oxide arranged in a side-by-side relationship with a fourth generally rectangular structural panel of magnesium oxide to define a second structural panel seam between the third and fourth structural panels. There is a second binding strip of magnesium oxide positioned over the second structural panel seam and fastened to form a lap joint with the third structural panel and with the fourth structural panel, so as to bond together the third and fourth structural panels. The second structural panel seam is offset from the foam panel seam a select distance in a direction generally perpendicular to the thickness; and the second structural layer is bonded to the second opposing face of the foam layer.

An enclosure member for a building structure comprising a planar laminate having a first facing layer; a layer of foam having a first face and a second opposing face; and a second facing layer; where the first facing layer is fastened to the first face of the layer of foam, and the second facing layer is fastened to the second opposing face of the layer of foam. An edge of the enclosure is provided with a perimeter structure that can perform one or more of a sealing function, an edge reinforcement function and a pivotable joining function with another enclosure, in accordance with the particular embodiment.

An enclosure member for a building structure comprising a planar laminate having a first facing layer; a layer of foam having a first face and a second opposing face; and a second facing layer; where the first facing layer is fastened to the first face of the layer of foam, and the second facing layer is fastened to the second opposing face of the layer of foam. An edge of the enclosure is provided with a perimeter structure that can perform one or more of a sealing function, an edge reinforcement function and a pivotable joining function with another enclosure, in accordance with the particular embodiment.

A foldable building structure is provided that includes a fixed space portion including a first floor portion, a first ceiling portion, and a first wall portion. The structure includes a second ceiling portion and a third ceiling portion each movable between a folded position that is proximate to the fixed space portion and a deployed position. The second and third ceiling portions are movable from their respective folded positions to their respective deployed positions to form with the first ceiling portion a ceiling component of the building structure when in their deployed positions, the ceiling component having a periphery. At least one of the first floor portion, the first ceiling portion, the second ceiling portion, or the third ceiling portion includes at least a section of a closed-loop passageway proximate to the periphery in the interior portion adapted to contain a utility line.

An enclosure member for a building structure comprising a planar laminate having a first facing layer; a layer of foam having a first face and a second opposing face; and a second facing layer; where the first facing layer is fastened to the first face of the layer of foam, and the second facing layer is fastened to the second opposing face of the layer of foam. An edge of the enclosure is provided with a perimeter structure that can perform one or more of a sealing function, an edge reinforcement function and a pivotable joining function with another enclosure, in accordance with the particular embodiment.