SUBASSEMBLY FOR ENCLOSURE COMPONENT MANUFACTURE

Abstract

An enclosure component having first surface layer, a core layer and a second surface layer. The core layer has three rectangular foam panels, each with a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges. The second and third foam panels are identical, and each has an internal passage between the first and second edges that is offset from the mid-point of the panel, and an elongate recess on a surface of the panel spanning the distance between the first and second edges. The fourth edge of the first panel is arranged side-by-side with the third edge of the second panel, and the third edge of the first panel is arranged side-by-side with the third edge of the third panel. An elongate reinforcement spline is in each recess. The first surface layer is bonded to the core layer, and the second surface layer is bonded to the core layer.

Claims

1. An enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising: a first surface layer having a first face and an opposed second face; a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component; the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension; the second and third foam panels each having (a) an internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges; the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel; an elongate reinforcement spline in each recess; a second surface layer having a first face and an opposed second face; and the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer.

2. The enclosure component of claim 1, wherein the core layer further comprises: a planar rectangular fourth foam panel and a planar rectangular fifth foam panel, each of the fourth and fifth foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fourth and fifth foam panels being oriented along the length of the enclosure component; the fourth edge of the fourth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the fourth edge of the fifth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel; and the first and second edges of each of the fourth and fifth foam panels each has a same third linear dimension that is different from the first linear dimension.

3. The enclosure component of claim 2, wherein the third linear dimension is less than the first linear dimension.

4. The enclosure component of claim 2, wherein the first edges of the first, second, third fourth and fifth foam panels are in aggregate equal to the length of the enclosure component.

5. The enclosure component of claim 1, wherein the third edge and the fourth edge of each of the first, second and third foam panels each equals the width of the enclosure component.

6. The enclosure component of claim 1, wherein the second and third foam panels are each symmetrical about a dividing line extending between the third and fourth edges and are each asymmetrical about a dividing line extending between the first and second edges.

7. The enclosure component of claim 1, wherein the internal passage of each of the second and third foam panels extends parallel to the recess and the internal passage and recess are offset from the fourth edge by an identical distance such that the internal passage and the recess are aligned within the thickness.

8. The enclosure component of claim 7, wherein the second and third foam panels include a further internal passage that is parallel to the recess and offset from the fourth edge a different distance than the recess.

9. The enclosure component of claim 1, wherein the internal passage in the first foam panel extends between the first and second edges midway between the third and fourth edges.

10. The enclosure component of claim 1, wherein one of the second or third foam panels is rotated one hundred eighty degrees relative to the other about an axis extending in a direction of the thickness that is perpendicular to the length and width.

11. The enclosure of component of claim 1, wherein each recess is formed on the second face of the core layer.

12. An enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising: a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component; a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component; the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension; the first and second edges of each of the first, second, third and fourth surface panels A each has a same third linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension; the second and third foam panels each having (a) a linear first internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges; the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel; the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A; an elongate reinforcement spline in each recess; a surface layer B having a first face and an opposed second face; and the second face of the surface layer A being bonded to the first face of the core layer, and the first face of the surface layer B being bonded to the second face of the core layer.

13. The enclosure component of claim 12, wherein the surface layer A further comprises: a planar rectangular fifth surface panel A and a planar rectangular sixth surface panel A, each of the fifth and sixth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fifth and sixth surface panels A being oriented along the length of the enclosure component; and the first and second edges of each of the fifth and sixth surface panels A each has a same fourth linear dimension that is different from the third linear dimension.

14. The enclosure component of claim 13, wherein the fourth linear dimension is less than the third linear dimension.

15. The enclosure component of claim 13, wherein the first edges of the first, second, third, fourth, fifth and sixth surface panels A are in aggregate equal to the length of the enclosure component.

16. The enclosure component of claim 12, wherein the third edge of the first, second, third, fourth, fifth and sixth surface panels A each equals the width of the enclosure component.

17. The enclosure component of claim 12, further comprising an elongate planar rectangular first joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the first joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge.

18. The enclosure component of claim 17, wherein the first joinder spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first joinder spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the first joinder spline being oriented along the length of the enclosure component, with each of the first and second edges of the first joinder spline having a linear dimension less than 50 percent of the third linear dimension.

19. The enclosure component of claim 18, wherein the first joinder spline is bonded to the first face of the core layer.

20. The enclosure component of claim 18, wherein the first and second edges of the first joinder spline have a linear dimension less than 25 percent of the third linear dimension.

21. The enclosure component of claim 18, wherein the first and second edges of the first joinder spline have a linear dimension less than 10 percent of the third linear dimension.

22. The enclosure component of claim 12, wherein the reinforcement spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the reinforcement spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the reinforcement spline being oriented along the length of the enclosure component, with each of the first and second edges of the reinforcement spline having a linear dimension less than fifty percent of the third linear dimension.

23. The enclosure component of claim 22, wherein the reinforcement spline is bonded to the core layer.

24. The enclosure component of claim 22, wherein the first and second edges of the reinforcement spline having a linear dimension less than 25 percent of the fourth linear dimension.

25. The enclosure component of claim 22, wherein the first and second edges of the reinforcement spline having a linear dimension less than 10 percent of the fourth linear dimension.

26. The enclosure component of claim 12, wherein the first joinder spline is steel.

27. The enclosure component of claim 12, wherein one or more of the surface panels A is cement board.

28. The enclosure component of claim 12, wherein the reinforcement spline is wooden.

29. The enclosure component of claim 12, wherein the surface layer B comprises: a planar rectangular first surface panel B and a planar rectangular second surface panel B, each of which has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, with the first and second edges being oriented along the length of the enclosure component; and the fourth edge of the first surface panel B arranged in a side-by-side relationship with the third edge of the second surface panel B.

30. The enclosure component of claim 12, further comprising an elongate planar rectangular second joinder spline overlapping the fourth edge of the first surface panel B and the third edge of the second surface panel B, the second joinder spline bonded to the first surface panel B proximate to its fourth edge and bonded to the second surface panel B proximate to its third edge.

31. The enclosure component of claim 30, wherein the second joinder spline is steel.

32. The enclosure component of claim 12, wherein the core layer includes a linear second internal passage parallel to the first internal passage, and a linear third internal passage parallel to the first internal passage, the first, second and third internal passages forming an internal passage array, the internal passages of which are spaced apart from each other by an integer multiple of a grid distance.

33. The enclosure component of claim 32, wherein the first surface layer includes a plurality of apertures proximate to an edge of the first surface layer that is along the length of the enclosure component, and the plurality of apertures are spaced apart from each other by one-half of an integer multiple of the grid distance.

34. The enclosure component of claim 33, wherein at least two of the plurality of apertures are bounded by at least two of the internal passages of the internal passage array, and each aperture of the at least two of the plurality of apertures is spaced apart from each passage of the at least two internal passages by an integer multiple of an offset distance.

35. The enclosure component of claim 34, wherein the offset distance is one-quarter the grid distance.

36. A foldable enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising: first and second enclosure component sub-portions, each such enclosure component sub-portion including: a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component; a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component; the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension; the first and second edges of each of the first, second, third and fourth surface panels A each has a same fourth linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension; the second and third foam panels each having an elongate recess on a surface of the panel spanning the distance between the first and second edges; the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel; the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A; an elongate reinforcement spline in each recess; an elongate planar rectangular joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge; a second surface layer having a first face and an opposed second face; and the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer; a beam assembly comprising a first beam joined to a second beam by a first hinge assembly defining a first hinge line; the first enclosure component sub-portion joined to the first beam and joined to the second beam; the second enclosure component sub-portion joined to the first beam and joined to the second beam; and the first enclosure component sub-portion divided along the first hinge line and the second enclosure sub-portion divided along the first hinge line to define a first enclosure component portion joined to the first beam and a second enclosure component portion joined to the second beam.

37. The foldable enclosure component of claim 36, wherein the beam assembly further comprises a third beam joined to the second beam by a second hinge assembly defining a second hinge line; the first enclosure component sub-portion is further joined to the third beam; the second enclosure component sub-portion is further joined to the third beam; and the first enclosure component sub-portion is further divided along the second hinge line and the second enclosure sub-portion is further divided along the second hinge line to define a third enclosure component portion joined to the third beam.

38. A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising: fabricating a first workpiece by performing at least the following steps: forming a first surface layer by arranging a plurality of planar rectangular first surface panels side-by-side to form one or more first seams between a respective one or more of the plurality of first surface panels; placing an elongate planar first joinder spline over one of the one or more first seams to form a first sub-assembly; forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel; forming a second surface layer by arranging a plurality of planar rectangular second surface panels side-by-side to form one or more second seams between a respective one or more of the plurality of second surface panels; placing a second elongate planar joinder spline over one of the one or more second seams to form a second sub-assembly; joining the first sub-assembly to the first face of the core layer; and joining the second sub-assembly to the second face of the core layer; thereby to fabricate the first workpiece.

39. A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising: fabricating a first workpiece by performing at least the following steps: placing at least two elongate planar rectangular first joinder splines spaced-apart a first select distance to form a first spline sub-assembly; forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel; joining the first spline sub-assembly to the first face of the core layer; placing at least two elongate planar rectangular second joinder splines spaced-apart a second select distance to form a second spline sub-assembly; joining the second spline sub-assembly to the second face of the core layer; forming a first surface layer by arranging three planar rectangular first surface panels side-by-side to provide a first middle panel flanked by a first pair of seams, where the first middle panel is dimensioned so that the first pair of seams is separated by the first select distance; joining the first surface layer to the first face of the core layer and the first spline sub-assembly positioned so that the first pair of seams overlie the first joinder splines; forming a second surface layer by arranging three planar rectangular second surface panels side-by-side to provide a second middle panel flanked by a second pair of seams, where the second middle panel is dimensioned so that the second pair of seams is separated by the second select distance; and joining the second surface layer to the second face of the core layer and the second spline sub-assembly positioned so that the second pair of seams overlie the second joinder splines; thereby to fabricate the first workpiece.

40. The method of claim 38, further comprising cutting an access point through the first surface layer to communicate with the internal passage.

41. The method of claim 38, further comprising cutting a door aperture or a window aperture through the workpiece.

42. The method of claim 38, further comprising cutting the first workpiece parallel to the third edge of the first foam panel into two enclosure component portions.

43. The method of claim 38, further comprising: fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece; providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line; cutting the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular second enclosure component sub-portion; cutting the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular third enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular fourth enclosure component sub-portion; joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.

44. The method of claim 38, further comprising: fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece; providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line, with a third beam having a third beam length joined to the second beam by a second hinge assembly defining a second hinge line; cutting in a first cutting step the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a first cut line from a planar rectangular second enclosure component sub-portion; cutting in a second cutting step the second enclosure component sub-portion parallel to the first cut line, and at a distance from a first cut line edge of the second enclosure component sub-portion equal to the second beam length, to form from the second enclosure component sub-portion a planar rectangular first enclosure component third sub-portion with a side having a linear dimension equal to the second beam length, separated along a second cut line from a planar rectangular fourth enclosure component sub-portion; cutting in a third cutting step the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular fifth enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a third cut line from a planar rectangular sixth enclosure component sub-portion; cutting in a fourth cutting step the sixth enclosure component sub-portion parallel to the third cut line, and at a distance from a third cut line edge of the sixth enclosure component sub-portion equal to the second beam length, to form from the sixth enclosure component sub-portion a planar rectangular enclosure component seventh sub-portion with a side having a linear dimension equal to the second beam length, separated along a fourth cut line from a planar rectangular eighth enclosure component sub-portion; joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.

45. A foldable enclosure component for a building structure, the enclosure component comprising: a floor component formed by: two of the enclosure components as recited in claim 1; and a first beam assembly positioned between and joined to the enclosure components of the floor component, the first beam assembly including a first beam and a second beam attached to the first beam by a first hinge to define a first hinge line along which the enclosure components are cut to define a first portion of the floor component and a second portion of the floor component pivotally joined to each other by the first hinge to allow the floor component to move between a folded position and an unfolded position; and a ceiling component formed by: two of the enclosure components as recited in claim 1; a second beam assembly positioned between and joined to the enclosure components of the ceiling component, the second beam assembly including a first beam, a second beam attached to the first beam by a first hinge to define a first hinge line, and a third beam attached to the second beam by a second hinge to define a second hinge line, the enclosure components of the ceiling component are cut to along the first and second hinge lines of the second beam assembly to define a first portion of the ceiling component, a second portion of the ceiling component pivotally joined to the first portion of the ceiling component by the first hinge, and a third portion of the ceiling component pivotally joined to the second portion of the ceiling component by the second hinge to allow the ceiling component to move between a folded position and an unfolded position.

46. A foldable enclosure component for a building structure, the enclosure component comprising: a floor component formed by: two of the enclosure components as recited in claim 12; and a first beam assembly positioned between and joined to the enclosure components of the floor component, the first beam assembly including a first beam and a second beam attached to the first beam by a first hinge to define a first hinge line along which the enclosure components are cut to define a first portion of the floor component and a second portion of the floor component pivotally joined to each other by the first hinge to allow the floor component to move between a folded position and an unfolded position; and a ceiling component formed by: two of the enclosure components as recited in claim 12; a second beam assembly positioned between and joined to the enclosure components of the ceiling component, the second beam assembly including a first beam, a second beam attached to the first beam by a first hinge to define a first hinge line, and a third beam attached to the second beam by a second hinge to define a second hinge line, the enclosure components of the ceiling component are cut to along the first and second hinge lines of the second beam assembly to define a first portion of the ceiling component, a second portion of the ceiling component pivotally joined to the first portion of the ceiling component by the first hinge, and a third portion of the ceiling component pivotally joined to the second portion of the ceiling component by the second hinge to allow the ceiling component to move between a folded position and an unfolded position.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1A is a perspective view of a folded building structure (a shipping module), and

[0010] FIG. 1B is a perspective view of an unfolded building structure.

[0011] FIG. 2 is a top schematic view of the structure shown in FIG. 1B.

[0012] FIG. 3 is an end view of a shipping module as shown in FIG. 1A, from which is formed the structure shown in FIG. 1B.

[0013] FIG. 4 is an exploded side view of the laminate structure design of the present inventions.

[0014] FIG. 5 is an exploded perspective view of an enclosure component workpiece of the present inventions.

[0015] FIG. 6 is a cutaway perspective view of the core layer of the present inventions.

[0016] FIG. 7 is a perspective view of an enclosure component workpiece of the present invention at one stage of being manufactured to form a wall component.

[0017] FIG. 8 is a perspective view of an enclosure component showing a cutaway of the core layer of two workpieces used to form the enclosure component of the present inventions.

[0018] FIG. 9A is a perspective view of a foldable I-beam for a floor component in accordance with the present inventions, in the beam unfolded position, and FIG. 9B is a side view of a foldable I-beam for a floor component in accordance with the present inventions, in the beam folded position.

[0019] FIG. 10 is a cutaway perspective view showing the placement of floor end hinge assemblies in the structure of a floor component in accordance with the present inventions.

[0020] FIG. 11A is a perspective view of a foldable I-beam for a roof component in accordance with the present inventions, in the beam unfolded position, and FIG. 11B is a side view of a foldable I-beam for a roof component in accordance with the present inventions, in the beam folded position.

[0021] FIG. 12 is a cutaway perspective view showing the placement of roof end hinge assemblies in the structure of a roof component in accordance with the present inventions.

[0022] FIG. 13 is perspective view providing a schematic illustration of the assembly of the major portions of a floor component of the present inventions.

[0023] FIG. 14 is perspective view providing a schematic illustration of the assembly of the major portions of a roof component of the present inventions.

[0024] FIG. 15A is a perspective view of a joinder spline of the present inventions, and FIG. 15B is a detailed perspective view of the barbs optionally provided on one or more joinder splines of the present inventions.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in FIGS. 1 through 3. When fully unfolded, as exemplified by FIG. 1B, 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. As shown in FIGS. 1B and 2, 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. For convenience, a direction parallel to 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; and a direction parallel to the vertical direction in FIG. 1B 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 embodiment of structure 150 shown in FIG. 1B is square in shape, approximately 19 feet (5.79 m) by 19 feet (5.79 m), although embodiments of the structure 150 can have different dimensions.

[0026] FIG. 2 shows a top schematic view of structure 150 shown in FIG. 1B, and includes a geometrical orthogonal grid, which is used to assist in the lay-out and assembly of the elements forming structure 150, as well as 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, with the mid-point grid line in the longitudinal direction designated as G.sub.L and the mid-point grid line in the transverse direction designated as G.sub.T (in this disclosure, reference simply to grid line G should be understood to refer to either). In the embodiment of structure 150 shown in FIG. 2, dimension E is 57 inches (144.8 cm), although embodiments of the structure 150 can have different E dimensions. The use of this grid system will be described further below.

Enclosure Component (155): General Description

[0027] The enclosure components 155 of the present invention include a number of shared design features that are described below.

[0028] A. Laminate Structure Design

[0029] Enclosure components 155 can be fabricated using a multi-layered, laminate design generally shown in FIG. 4. The elements of this multi-layered, laminate design comprise a core layer 160, a first surface layer 210 and a second surface layer 215.

[0030] First surface layer 210 comprises two or more planar rectangular first surface panels 211, m in number, where the ith first surface panel 211 is represented by 211.sub.i, and i=1, 2, . . . m. In the case where i2, m number of first surface panels 211 are arranged in a side-by-side, contacting relationship (first surface panel 211.sub.k, first surface panel 211.sub.k+1, where 1<km) to form a first surface layer 210 of arbitrary length. An elongate planar rectangular joinder spline 213 overlaps the kth first surface panel 211.sub.k and the adjacent k+1th surface panel 211.sub.k+1. Joinder spline 213 is shown in FIG. 15A. Each joinder spline 213 underlies a narrow portion of each of the adjacent first surface panels 211.sub.k, 211.sub.k+1. First surface panels 211 can be for example fiber cement board or magnesium oxide (MgO) board. The joinder splines 213 can be steel strip stock. Joinder splines 213 can be fastened to first surface panels 211 by adhesive, mechanical fasteners or a combination thereof.

[0031] Second surface layer 215 has a construction similar to first surface layer 210. In particular, second surface layer 215 comprises two or more planar rectangular second surface panels 216, n in number, where the ith second surface panel 215 is represented by 215.sub.i, and i=1, 2, . . . n. In the case where i2, n number of second surface panels 216 are arranged in a side-by-side, contacting relationship (second surface panel 216.sub.k, second surface panel 216.sub.k+1, where 1<kn) to form a second surface layer 215 of arbitrary length. An elongate planar rectangular joinder spline 217 overlaps the kth second surface panel 216.sub.k and the adjacent k+1th second surface panel 216.sub.k+1. Joinder spline 217 in the described embodiment is the same as joinder spline 213 (but need not be), and is also shown in FIG. 15A. Each joinder spline 217 underlies a narrow portion of each of the adjacent second surface panels 216.sub.k, 216.sub.k+1. Second surface panels 216 can be for example fiber cement board or magnesium oxide (MgO) board. The joinder splines 217 can be steel strip stock. Joinder splines 217 can be fastened to second surface panels 216 by a suitable adhesive, preferably a polyurethane based construction adhesive, by mechanical fasteners, or by a combination thereof.

[0032] Core layer 160 is sandwiched between first surface layer 210 and second surface layer 215. Core layer 160 comprises a plurality of generally planar rectangular foam panels 214, p in number, where the ith foam panel 214 is represented by 214.sub.i, and i=1, 2, . . . p. In the case where i2, p number of foam panels 214 are arranged in a side-by-side, contacting relationship (foam panel 214.sub.k, foam panel 214.sub.k+1, where 1<kp) to form a planar core layer 160 of arbitrary length, collectively presenting a planar first face and an opposing planar second face. The first face of core layer 160 is bonded to first surface layer 210 using for example a suitable adhesive, preferably a polyurethane based construction adhesive, and the second face of core layer 160 is bonded to second surface layer 215 using for example a suitable adhesive, preferably a polyurethane based construction adhesive. There is a seam 218 between adjacent foam panels 214. Foam panels 214 are made for example of expanded polystyrene (EPS) or polyurethane foam.

[0033] There are additionally provided a plurality of planar elongate reinforcement splines 221 spaced-apart across the length of core layer 160, as shown in FIGS. 4 and 5. Reinforcement splines 221 are received in recesses 222 cut into foam panels 214 to permit the second surface panels 216 to lie flat against core layer 160. Reinforcement splines 221 are made for example of lumber. Reinforcement splines 221 improve the bending resistance of the enclosure component 155. In the embodiment shown, reinforcement splines 221 are provided on only one face of core layer 160, and preferably are disposed on the face that is distal from the interior of the structure 150. Optionally, reinforcement splines 221 can be provided in recesses 222 on both faces of core layer 160.

[0034] As can be seen in the example of FIG. 4, the joinder splines 213 and 217 do not overlie the seams 218, but rather are offset a select distance so that the seams between and in each of the first surface layer 210 and second surface layer 215 do not match up with the seams 218 of core layer 216 across the thickness of enclosure component 155.

[0035] B. Enclosure Component Exterior Edge Reinforcement

[0036] 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.

[0037] C. Enclosure Component Partitioning

[0038] Enclosure components 155 in certain instances are partitioned into enclosure component portions to facilitate forming a compact shipping module 15. 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.

[0039] 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.

[0040] D. Enclosure Component Interior Edge Reinforcement

[0041] 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.

[0042] E. Enclosure Component Sealing Systems

[0043] 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.

[0044] Particular sealing structures for accomplishing the foregoing objective are described in U.S. Non-Provisional patent application Ser. No. 17/504,883, filed on Oct. 19, 2021, entitled Sheet/Panel Design for Enclosure Component Manufacture and having the same inventors as the present application, and 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 U.S. Non-Provisional patent application Ser. No. 17/504,883, filed on Oct. 19, 2021, entitled Sheet/Panel Design for Enclosure Component Manufacture and having the same inventors as the present application, are hereby incorporated by reference as if fully set forth herein, particularly including the sealing systems described for example at 0083-0170 and depicted in FIGS. 10-20 thereof, and also including the exemplary placements for such sealing systems described in 0171-0177 and depicted in FIGS. 21A-21B 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 the present application, are also 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.

[0045] F. Enclosure Component Load Transfer

[0046] 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).

[0047] For this purpose, multi-layered, laminate design shown in FIG. 4 will function to transfer the loads described above. To add additional load transfer capability, structural members, such as beams and/or joists, can be utilized within the perimeter of the enclosure components 155, as is deemed appropriate to the specific design of structure 150 and the particular enclosure component 155, to assist in the transfer of loads to the exterior edges. Particular embodiments of such structural members which can be used in floor components 300 and roof components 400, which also incorporate hinge structures, are described below.

[0048] G. Enclosure Component Manufacture

[0049] It is preferred that each enclosure component 155that is to say, all wall components 200, all floor components 300 and all roof components 400be fabricated from a common subassembly, referred to herein as enclosure component workpiece 250.

[0050] An embodiment of workpiece 250 is shown in exploded form in FIG. 5. In this embodiment, first and second surface layers 210, 215 can be cement board, joinder splines 213, 217 can be steel strip, and reinforcement spline 221 can be lumber.

[0051] The workpiece 250 in the FIG. 5 embodiment uses six planar rectangular first surface panels 211 for first surface layer 210. Four of these first surface panels 211 have the same width and length (X, Y direction respectively in FIG. 5), and are designated 211-1 in FIG. 5. In the preferred embodiment, the remaining two of the six first surface panels 211, designated 211-2 in FIG. 5, each has the same length as first surface panels 211-1, but is smaller in width than first surface panels 211-1. Each first surface panel 211-2 of the workpiece 250 has the same length and width as the other first surface panel 211-2. Accordingly, from a manufacturing standpoint two stock keeping units, or SKUs, can be utilized to form the first surface layer 210 of the workpiece 250.

[0052] The workpiece 250 in the FIG. 5 embodiment also uses six planar rectangular second surface panels 216 for second surface layer 215. Four of these second surface panels 211 have the same length and width, and are designated 216-1 in FIG. 5. In the preferred embodiment, the remaining two of the six second surface panels 216, designated 216-2 in FIG. 5, each has the same length as first surface panels 216-1, but is smaller in width than first surface panels 216-1. Each second surface panel 216-2 of the workpiece 250 has the same length and width as the other second surface panel 216-2. Accordingly, from a manufacturing standpoint two SKUs can be utilized to form the second surface layer 215 of the workpiece 250.

[0053] In the embodiment shown in FIG. 5, each first surface panel 211 can be 114 inches (2.9 m) long (Y direction in FIG. 5), and that each second surface panel 216 also can be 114 inches (2.9 m) long. As indicated above, it is preferred that first surface panels 211 be provided in two widths (X direction in FIG. 5). Thus in the FIG. 5 embodiment, there can be a first width of 48 inches (1.22 m) for first surface panel 211-1, and a second width of 18 inches (0.46 m) for first surface panel 211-2. Likewise, it is preferred that second surface panels 216 also be provided in two widths. Thus in the FIG. 5 embodiment, there can be a first width of 48 inches (1.22 m) for second surface panel 216-1, and a second width of 18 inches (0.46 m) for second surface panel 216-2. First surface panels 211 and second surface panels 216 can be for example 0.3125 in (0.7938 cm) thick cement board. In the case where first surface layer 210 and second surface layer 215 are made of the same material, then the first and second surface layers 210, 215 of workpiece 250 can be fabricated using but two SKUs.

[0054] The workpiece 250 additionally uses five planar rectangular foam panels 214 for core layer 160, each preferably having the same length (Y-direction in FIG. 5) as surface panels 211, 216; thus if surface panels 211, 216 are 114 inches (2.9 m) long, then foam panels preferably are 114 inches (2.9 m) long. Each of the foam panels 214 is provided with one or more elongate vertically-oriented internal passageways extending parallel to the y-axis, referred to as vertical chases 219, spanning the distance between their top and bottom edges. Vertical chases 219 facilitate the installation of utility lines. The foam panels 214 in the depicted embodiment are also provided with one or more horizontal internal passageways, referred to as horizontal chases 207, which span the width of foam panels 214. The horizontal chases 207 extend parallel to the X-axis in FIG. 5, perpendicular to the Y-axis, and generally in the same plane as the vertical chases 219 such that and the horizontal chases 207 intersect vertical chases 219. Horizontal chases 207 facilitate wiring across enclosure component 155. The vertical chases 219 and horizontal chases 207 are formed in and completely surrounded by the foam of the foam panels along their lengths, except that the ends of the vertical chases 219 and horizontal chases 207 can be accessible at one or more edges of the work piece 250 and/or the vertical chases 219 and horizontal chases 207 can be accessed via any cutout formed in the workpiece 250. Reference to vertical, horizontal, top and bottom with respect to the workpiece 250 is provided to illustrate a relative relationship of the components that form the workpiece 250 as it is illustrated in FIGS. 5 and 6, not necessarily relative to the shipping module 15 or structure 1250. For example, as the workpieces 250 can be utilized to form a wall component 200, a floor component 300, and a roof component 400, the orientation of the workpieces will vary.

[0055] The placement of vertical chases 219 and horizontal chases 207 in foam panels 214 is shown in the cross-section of core layer 160 of FIG. 6 taken along the X-Y axis. It is preferred that vertical chases 219 be uniformly spaced apart a distance equal to 0.5E, which in the embodiment shown is a distance of 28.5 inches (72.4 cm). It is additionally preferred that one of the vertical chases 219, denominated 219.sub.C in FIG. 6, be positioned at the X-direction mid-length point of core layer 160 (see FIG. 6), and that the remaining chases 219 be spaced outward 0.5E to each side of that mid-length point vertical chase 219.sub.C. It is further preferred that there be an even number of horizontal chases 207 symmetrically placed above and below the Y-direction mid-length point of core layer 160; in the embodiment shown in FIG. 6, there are two such horizontal chases 207 in core layer 160. In the case where foam panels 214 are 114 inches (2.9 m) long (Y direction in FIG. 5), then the first such horizontal chase 207 can be positioned 16 inches (40.6 cm) above the bottom edge of core layer 160 (Y direction in FIG. 6), and the second such horizontal chase 207 can be positioned 16 inches (40.6 cm) below the top edge of core layer 160. The horizontal chases 207 in each of the adjacent foam panels 214 are aligned to provide a path of communication across the length (X direction in FIG. 6) of the workpiece 250.

[0056] The vertical and horizontal passageways in foam panels 214 defining vertical and horizontal chases 219 and 207 preferably are formed prior to assembly of foam panels 214 into the laminate multi-layer structure of workpiece 250. These passages can be formed for example by use of a hot wire shaped and directed to form within panels 214 a cylindrical or other desired closed shape, thereby forming a foam plug severed from the bulk foam. Removal of the foam plug yields the desired passageway defining a vertical chase 219 or a horizontal chase 207.

[0057] Each chase 207, 219 preferably is provided with a diameter sufficient to permit the installation of utility lines. The vertical chase 219 in each foam panel 214-3, designated 219W in FIG. 6, can be made larger in cross-section than the vertical chases in other locations. In the embodiment shown in FIG. 6, the two horizontal chases 207 shown running through the foam panels 214 each has the same area in cross-section as vertical chases 219W. Thus each vertical chase 219W has an oval shape with a major diameter for example of approximately 5 inches (12.7 cm), and each horizontal chase 207 in foam panels 214-1, 214-2 and 214-3 has an oval shape with a major diameter of approximately 5 inches (12.7 cm). In comparison, each of the vertical chases 219 in foam panels 214-1 and 214-2 has a circular shape with a diameter of approximately 1.5 inches (3.8 cm). Notably, a loop pathway, utility service sub-system 460, can be traced through vertical chases 219W and horizontal chases 207 in the foam panels 214 (shown as a dashed line in FIG. 6), which sub-system is generally located about the periphery of work piece 250, and through which utility trunk lines can be conveniently routed and connected to service lines.

[0058] On one of the faces of the foam panels 214 for core layer 160, there are provided at select intervals, the recesses 222 that will receive reinforcement splines 221. It is preferred that the recesses 222 be uniformly spaced apart a distance equal to E, which in the embodiment shown is a distance of 57 inches (145 cm). It is additionally preferred that the recesses 222 (and the reinforcement splines 221 therein) be symmetrically positioned to each side of the X-direction mid-point of core layer 160.

[0059] The X-direction mid-point of one of these foam panels 214, designated 214-1 in FIG. 5, is positioned to coincide with the X direction mid-point (in FIG. 5) of the workpiece 250. The width of foam panel 214-1 in the FIG. 5 embodiment is 48 inches (1.22 m). Further, when workpiece 250 is utilized in accordance with the manufacturing sequences described below, and if the workpiece 250 is used to fabricate: [0060] (a) a wall component 200, then foam panel 214-1 will be located at the mid-point of the wall component 200; or [0061] (b) a floor component 300, then foam panel 214-1 will be located at the mid-point of the floor component (in the transverse direction); or [0062] (c) a roof component 400, then foam panel 214-1 will be located at the mid-point of the roof component (in the transverse direction).

[0063] Further, foam panel 214-1 preferably is symmetric about its X and Y axes; i.e., the vertical chase 219 and horizontal chases 207 in foam panel 214-1 are symmetrically located within foam panel 214-1 about the X, Y axes bisecting foam panel 214-1. In the preferred embodiment, workpiece 250 includes only one foam panel 214-1. In the embodiment shown in FIG. 5, there is but one vertical chase 219, chase 219.sub.C as previously noted, located at the Y axis bisecting foam panel 214-1. As may be appreciated from the foregoing, and as illustrated in FIG. 6, vertical chase 219.sub.C will coincide with one of the mid-point grid lines G, the particular one (G.sub.L or G.sub.T) depending upon the enclosure component 155 in which the workpiece 250 is used.

[0064] The foam panels 214 placed to each side of foam panel 214-1 and in contact with foam panel 214-1 are designated as foam panels 214-2 in FIG. 5. In the embodiment shown, each foam panel 214-2 is symmetric about its X axis, but not about its Y axis; i.e., the horizontal chases 207 in foam panel 214-2 are symmetrically located about the X axis bisecting foam panel 214-2 (and align with the horizontal chases 207 in foam panel 214-1), but the vertical chases 219 are not symmetrically located about the Y axis bisecting foam panel 214-2.

[0065] In the embodiment shown in FIG. 5, the width of foam panel 214-2 is 48 inches (1.22 m). There is a first vertical chase 219 located in foam panel 214-2, spaced preferably 0.5 E from vertical chase 219.sub.C, which in the embodiment depicted is 4.5 inches (11.43 cm) from the edge of foam panel 214-2 abutting foam panel 214-1. In addition, there is a second vertical chase 219 located in foam panel 214-2, spaced preferably E from vertical chase 219.sub.C, which in the embodiment depicted is thirty three inches (83.8 cm) from the edge of foam panel 214-2 abutting foam panel 214-1. Furthermore, on one face of foam panel 214-2, there is provided a recess 222, which after assembly of work piece 250 preferably is located a distance E from the X-direction mid-point of foam panel 214-1, which location in the embodiment depicted is 4.5 inches (11.43 cm) from the edge of foam panel 214-2 abutting foam panel 214-1. This recess 222 when so positioned will overlie the vertical chase 219 located in foam panel 214-2 which is preferably spaced 0.5 E from vertical chase 219.sub.C, as can be seen in FIG. 6.

[0066] In assembly, one of the foam panels 214-2 is rotated 180 degrees (180) about its Z axis relative to the other of the foam panels 214-2, to result in the vertical chases 219 in foam panels 214-2 to be symmetrically located about the Y axis bisecting foam panel 214-1. For this reason, one of the foam panels 214-2 in FIG. 5 is designated 214-2U, and the other is designated 214-2D, to reflect their different orientations.

[0067] The foam panels placed to each side of foam panels 214-2 in FIG. 5 are designated foam panels 214-3. In the embodiment shown, each foam panel 214-3 is symmetric about its X axis, but not about its Y axis; i.e., the horizontal chases 207 in foam panel 214-3 are symmetrically located about the X axis bisecting foam panel 214-3 (and align with the horizontal chases 207 in foam panel 214-2), but the vertical chases 219 are not symmetrically located about the Y axis bisecting foam panel 214-3.

[0068] In the embodiment shown in FIG. 5, the width of foam panel 214-3 is 42 inches (1.07 m). There is a first vertical chase 219 located in foam panel 214-3, spaced preferably 1.5 E from vertical chase 219.sub.C, which in the embodiment depicted is 13.5 inches (34.3 cm) from the edge of foam panel 214-3 abutting foam panel 214-2. In addition, there is a second vertical chase 219 located in foam panel 214-3, spaced preferably 2E from vertical chase 219.sub.C, which in the embodiment depicted is at the exterior edge of foam panel 214-3; i.e., 42 inches (106.7 cm) from the edge of foam panel 214-2 abutting foam panel 214-3. Furthermore, on one face of foam panel 214-3, there is provided a recess 222, which after assembly of work piece 250 preferably is located a distance 1.5E from the Y direction mid-point of foam panel 214-1, which location in the embodiment depicted is 13.5 inches (34.3 cm) from the edge of foam panel 214-3 abutting foam panel 214-2. This recess 222 when so positioned will overlie the vertical chase 219 located in foam panel 214-3 which is also preferably spaced 1.5 E from vertical chase 219.sub.C.

[0069] In assembly, one of the foam panels 214-3 is rotated 180 degrees (180) about its Z axis (see FIG. 5) relative to the other of the foam panels 214-3, to result in the vertical chases 219 in foam panels 214-3 to be symmetrically located about the Y axis bisecting foam panel 214-1. For this reason, one of the foam panels 214-3 in FIG. 5 is designated 214-3U, and the other is designated 214-3D, to reflect their different orientations.

[0070] As is evident from the foregoing, from a manufacturing standpoint five panels with three SKUs can be utilized to form the foam layer 160 of the workpiece 250, namely foam panels 214-1 (one panel), 214-2 (two panels) and 214-3 (two panels). If first surface panels 211 and second surface panels 216 are 0.3125 in (0.7938 cm) thick, and if the foam panels 214 are made 5.375 in (13.65 cm) thick, then workpiece 250 will have an overall thickness of 6 in (15.24 cm).

[0071] FIG. 5 depicts a number of spaced-apart toe screw apertures 287 in each of the four first surface panels 211-1. In the event that workpiece 250 is to be used to manufacture wall component 200, these apertures 287 can be provided to receive toe screw housings which facilitate fastening the wall component 200 to a floor component 300. In use, a toe screw housing is inserted into a toe screw aperture 287, following which a fastener, such as a SIP screw, can be inserted and driven into the underlying exterior edge reinforcement of both the wall component 200 and the underlying floor component 300, to fasten the wall component 200 to the floor component 300. A detailed description of the construction of one embodiment of a toe screw housing is set forth in U.S. Non-Provisional patent application Ser. No. 17/587,051 entitled Wall Component Appurtenances, filed Jan. 28, 2022 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/587,051 entitled Wall Component Appurtenances, filed Jan. 28, 2022 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of toe screw housing 288, set forth for example in 0048-0055 and in FIGS. 8A-8C thereof. Toe screw apertures 287 need not be provided in work pieces 250 intended for use in floor components 300 or roof components 400.

[0072] It is desirable for toe screw apertures 287 not to overlie any of the vertical chases 219, so as to avoid a fastener being driven through for example electrical wiring running through chases 219. In this regard, when the preferred dimensional relationships and dimensions for workpiece 250 described above are employed, the seam between the inner two first surface panels 211-1 will overlie the chase 219.sub.C in foam panel 214-1. Thus, by placing the first aperture 287 to each side of this seam a distance equal to 0.125E, or 7.125 inches (18.1 cm), and spacing apart each succeeding aperture 287 a distance equal to 0.25E, or 14.25 inches (36.2 cm), the toe screw apertures 287 will not overlie any of the vertical chases 219. This spacing pattern for toe screw apertures 287 is shown in FIG. 5. Optionally, where the manufacture of a workpiece 250 is intended for a wall component 200, the cutting of apertures 287 can be performed on individual panels 211 prior to assembling first surface layer 210.

[0073] In the embodiment of FIG. 5, joinder splines 213, 217 can be steel strip 112 to 114 inches (2.84 to 2.90 m) in length (Y axis in FIG. 5), four inches (10.16 cm) in width (X axis in FIG. 5) and 0.024 inch (0.061 mm) thick (Z axis in FIG. 5). In turn, reinforcement splines 221 can be lumber 112 to 114 inches (2.84 to 2.90 m) in length (Y axis in FIG. 5), 3.5 inches (8.89 cm) in width (X axis in FIG. 5) and 1.5 inches (3.81 cm) thick (Z axis in FIG. 5).

[0074] The sequence for manufacturing workpiece 250 can proceed in various ways. A first manufacturing sequence proceeds as follows: [0075] (a) The first surface layer 210 is formed by arranging six first surface panels 211 side-by-side on a first assembly table in the following positional relationships, as shown in FIG. 5: 211-2/211-1/211-1/211-1/211-2. [0076] (b) Five joinder splines 213 are then placed on the five seams of these side-by-side positioned first surface panels 211. The splines 213 can be fastened to the first surface panels which they overlap with a suitable adhesive, such as a polyurethane based construction adhesive, or by use of mechanical fasteners, or by use of a combination thereof. In this regard, each spline 213 is optionally provided with spaced-apart barbs 212 extending from the plane of spline 213 on one side thereof, which are shown in FIG. 15B. These barbs 212 assist in keeping the spline 213 in place during manufacture. [0077] (c) Preferably concurrently with formation of the first surface layer 210, core layer 160 is formed by arranging five foam panels 214 side-by-side on a second assembly table in the following positional relationships and orientations, as shown in FIG. 5: 214-3D/214-2D/214-1/214-2U/214-3U. [0078] (d) A suitable adhesive, such as a polyurethane based construction adhesive, is then applied across the exposed face of first surface layer 210, and foam panel layer 160 is moved from the second work table as a unit and placed on that exposed, adhesive-bearing face of first surface layer 210. Notably, the foam panel layer 160 is oriented so that the recesses 222 cut into foam panels 214 are exposed, and not face-down against first surface layer 210. [0079] (e) Following positioning of foam panel layer 160 on first surface layer 210 as described above, the assembly is moved into a press table, such as a hydraulically or pneumatically actuated press table, which causes the assembly to be pressed together to thereby bond the first surface layer 210 to core layer 160. The bonded assembly is then moved out from the press table, and reinforcement splines 221 are positioned in recesses 222 and optionally bonded therein. [0080] (f) Preferably overlapping in time with the performance of at least some of the foregoing manufacturing steps, the second surface layer 215 is formed by arranging six first surface panels 216 side-by-side on an assembly table (which may or may not be same as the first assembly table or the second assembly table, depending on availability) in the following positional relationships, as shown in FIG. 5: 216-2/216-1/216-1/216-1/216-2. Five joinder splines 217 are then placed on the five seams of these side-by-side positioned second surface panels 216. The splines 217 can be fastened to the first surface panels which they overlap with a suitable adhesive, such as a polyurethane based construction adhesive, or by use of mechanical fasteners, or by use of a combination thereof. In this regard, each spline 217 is optionally provided with spaced-apart barbs 212 extending from the plane of spline 217 on one side thereof, which are shown in FIG. 15B. These barbs 212 assist in keeping the spline 217 in place during manufacture. [0081] (g) Following the positioning of reinforcement splines 221 in recesses 222, a suitable adhesive, such as a polyurethane based construction adhesive, is applied across the exposed face of core layer 160, and second surface layer 215 is moved from the work table as a unit and placed on the exposed, adhesive-bearing face of core layer 160. The assembly is next moved into a press table, which causes the assembly to be pressed together to thereby bond the second surface layer 215 to core layer 160. [0082] (h) The bonded assembly is then moved out from the press table, where all edges can optionally be given a clean-up cut. Workpiece 250 is then made available for utilization in the fabrication of wall component 200, floor component 300, and roof component 400.

[0083] Alternatively, a second manufacturing sequence proceeds as follows: [0084] (a) Five joinder splines 213 are placed on an assembly table and separated by a distance from each other to correspond to the distance between the locations where will be each of the five seams of first surface panels 211. Locating features, such as recesses or pins, can be provided on the assembly table to assist manufacturing personnel in placing the joinder splines 213 at their proper locations. [0085] (b) A suitable adhesive, such as a polyurethane based construction adhesive, is then applied to the exposed faces of the five joinder splines 213. [0086] (c) Core layer 160 is then formed by arranging five foam panels 214 side-by-side on the assembly table, overlying the five joinder splines 213, in the following positional relationships and orientations, as shown in FIG. 5: 214-3D/214-2D/214-1/214-2U/214-3U. Further the foam panels 214 are oriented so that their recesses 222 are face-up. [0087] (d) A suitable adhesive, such as a polyurethane based construction adhesive, is then applied across the exposed face of core layer 160, at least at positions spaced apart to correspond the distance between the joinder splines 217, and the five joinder splines 217 are placed at their appropriate locations on core layer 160, which now present a layer of adhesive. [0088] (e) Optionally with or following the foregoing assembly step (d), a suitable adhesive, such as a polyurethane based construction adhesive, can be applied in the recesses 222 of the exposed face of core layer 160, and the reinforcement splines 221 can be positioned in the recesses 222. [0089] (f) Preferably overlapping in time with the performance of at least some of the foregoing manufacturing steps, six first surface panels 211 are arranged side-by-side on a lamination table in the following positional relationships, as shown in FIG. 5: 211-2/211-1/211-1/211-1/211-2. [0090] (g) The exposed faces of first surface panels 211 are coated with a suitable adhesive, such as a polyurethane based construction adhesive, and the sub-assembly comprising core layer 160 and splines 213, 217 and 221 are placed on first surface panels 211, with the side having splines 213 oriented to be in contact with first surface panels 211. [0091] (h) Following positioning of core layer 160 on first surface panels 211 as described above, a suitable adhesive, such as a polyurethane based construction adhesive, is applied across the entire expose face of core layer 160, as well as the exposed faces of the five joinder splines 217 and reinforcement splines 221. [0092] (i) Preferably overlapping in time with the performance of at least some of the foregoing manufacturing steps, the second surface layer 215 is formed by arranging six first surface panels 216 side-by-side on the assembly described above, in the following positional relationships, as shown in FIG. 5: 216-2/216-1/216-1/216-1/216-2. [0093] (j) The assembly is moved into a press table, such as a hydraulically or pneumatically actuated press table, which causes the assembly to be pressed together to thereby bond the first surface layer 210 to core layer 160, and the second surface layer 215 to core layer 160.

[0094] As shown in FIG. 8, certain enclosure components 155, such as the floor component 300 and ceiling component 400, can include two identical workpieces 250 joined together along their length by an enclosure component beam assembly 525 (e.g., which can be embodied as floor beam assembly 325 or roof beam assembly 425 described herein) such that the enclosure component beam assembly 525 is positioned between the two workpieces 250. As described herein, the workpiece 250 can each include the vertical chases 219 and horizontal chases 207, where vertical chases 219W and the horizontal chases 207 can define the utility service sub-systems 460, one in each of the workpieces 250. Additionally, when the workpieces 250 are joined by the enclosure component beam assembly 525, the workpieces 250 are aligned so that the vertical chases 219W of each work piece are aligned with each other. The beam assembly can include openings 527 that also align with the vertical chases 219W such that the aligned vertical chases 219W on opposite sides of the beam assembly can be in communication with each other. In this configuration, the vertical chases 219W and the horizontal chases 207 that are proximate to a periphery of the enclosure component can form a closed path or loop, utility service system 470 that extends through the two workpieces 250 and the beam assembly 525. As further described herein the enclosure component beam assembly 525 can be formed of multiple beams joined together by one or more hinges (e.g., beam assemblies 325 and 425) and the workpieces 250 can be cut along hinge lines to allow the enclosure components to move between a folded position and an unfolded position. As may be understood, utility service system 470 is generally located about the periphery of the enclosure component 155 and comprises major portions of the vertical chases 219W and major portions of the horizontal chases 207 proximate the edges of the enclosure component 155. Utility service system 470 is a pathway through which utility trunk lines can be conveniently routed and connected to service lines, and also provides communication between the two utility service sub-systems 460 in the work pieces 250.

[0095] Further design details of wall component 200, floor component 300, and roof component 400 are provided in the sections following, as well as the further steps to fabricate each of the foregoing using one or more workpieces 250.

Wall Component (200)

[0096] Typically, structure 150 will utilize four wall components 200, with each wall component 200 corresponding to an entire wall of structure 150.

[0097] A. General Description

[0098] Wall component 200 has a generally rectangular perimeter. As shown in FIG. 1B, 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. In this disclosure, 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.

[0099] B. Partitioned Wall Components

[0100] Referring to FIG. 2, structure 150 has two opposing partitioned wall components 200, generically denominate 200s. One of the two opposing partitioned wall components 200s comprises first wall portion 200s-1 and second wall portion 200s-2, and the other of the two opposing partitioned wall components 200s 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. As shown in FIG. 2, 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, and 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.

[0101] Referring again to FIG. 2, first wall portion 200s-1 is fixed in position on floor portion 300a proximate to first transverse edge 108, and 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, and 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.

[0102] Notably, first wall portion 200s-1 is greater in length (the dimension in the transverse direction) than the length of 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 in length than the length of 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, 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. When 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. When wall portion 200s-2 is in its unfolded position (200s-2u), it forms with wall portion 200s-1 a wall component 200s 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 200s proximate second transverse edge 110.

[0103] C. Unpartitioned Wall Components

[0104] 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 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, sometimes denominated 200R in this disclosure, 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.

[0105] D. Wall Component Fabrication

[0106] Fabrication of Partitioned Wall Components

[0107] In the structure 150 shown in FIG. 1B, where wall components 200 are six inches (15.2 cm) thick, the partitioned wall components 200s are one foot smaller in length than wall components 200R and 200P. Accordingly, to make a partitioned wall component 200s, a workpiece 250 is subject to the following steps: [0108] (1) Six inches (15.2 cm) of material are vertically cut using for example a laser or waterjet cutter from each vertical side (Y direction in FIGS. 5 and 7) of the workpiece 250. [0109] (2) Any door apertures 202 and window apertures 204 are cut in workpiece 250 as desired, and any electrical, plumbing or other utility access points 276 are cut in workpiece 250 as desired, to yield a workpiece 250 in the state shown in FIG. 7. In addition, if toe screw apertures 287 were not previously formed in first surface layer 210, then they too can be cut at this point. [0110] (3) The workpiece 250 is cut in the vertical direction (Y direction in FIG. 7) at the appropriate location (in the case of wall portions 200s-3 and 200s-4, along line B in FIG. 7) to yield wall portions 200s-1 and 200s-2, or, as shown in FIG. 7, wall portions 200s-3 and 200s-4. [0111] (4) Exterior and interior edge reinforcement, together with the desired sealing structures, are positioned and bonded to the interior and exterior edges of the workpiece 250. [0112] (5) The workpiece 250 is painted, following which the hinge structures for joining the wall portion 200s-1 with wall portion 200s-2, or wall portion 200s-3 with wall portion 200s-4, are also added, to complete the wall component 200s.

[0113] Fabrication of Unpartitioned Wall Components

[0114] To make a wall component 200P or a wall component 200R, a workpiece 250 is subject to the following steps: [0115] (1) Any door apertures 202 and window apertures 204 are cut in workpiece 250 as desired, and any electrical, plumbing or other utility access points are cut in workpiece 250 as desired. In addition, if toe screw apertures 287 were not previously formed in first surface layer 210, then they too can be cut at this point. [0116] (2) Exterior edge reinforcement, together with the desired sealing structures, are positioned and bonded to the exterior edges of the workpiece 250. [0117] (3) The workpiece 250 is painted, to complete structure of the wall component 200P or 200R, as the case may be.

[0118] Floor Component (300)

[0119] Typically, structure 150 will utilize one floor component 300; thus floor component 300 generally is the full floor of structure 150.

[0120] A. General Description

[0121] Floor component 300 has a generally rectangular perimeter and can be fabricated using one or more workpieces 250. The length and width of floor component 300 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIGS. 1B and 2, floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).

[0122] B. Floor Partitioning

[0123] 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.

[0124] Referring to structure 150 shown in FIG. 2, 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 FIGS. 2 and 4, where floor portion 300b is horizontally oriented and co-planar with floor portion 300a.

[0125] C. Hinged Vertical Load Transfer Components for Floor Component (300)

[0126] FIG. 9A shows a floor beam assembly 325 that can be placed within floor component 300 to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne by floor component 300 to its edges. Floor beam assembly 325 includes two I-beams 326a and 326b. I-beam 326a is positioned approximately in the middle of floor portion 300a, I-beam 326b is positioned approximately in the middle of floor portion 300b, and each of I-beams 326a and 326b is oriented in the transverse direction. A hinge assembly 329A joins I-beam 326a to I-beam 326b. The hinge assembly 329A permits floor beam assembly 325 to be folded to a beam folded position shown in FIG. 9B and unfolded to a beam unfolded position shown in FIG. 9A. The I-beams 326a and 326b extend parallel to the transverse direction in the unfolded position. Further, the hinge assembly 329A can be locked when beam assembly 325 is in the beam unfolded position, which transforms floor beam assembly 325 into a rigid structure that will reinforce floor component 300 in the direction perpendicular to its axis of folding.

[0127] Hinge assembly 329A comprises two identical hinge assembly portions 330A partnered together to form a pivoted junction, as shown in FIGS. 9A and 9B. A detailed description of the construction of hinge assembly 329A and its hinge assembly portions 330A is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled Folding Beam Systems, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled Folding Beam Systems, filed Nov. 16, 2021 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of hinge assembly 329A and its hinge assembly portions 330A set forth for example in 0075-0087 and in FIGS. 9-12 and 13C-13E thereof.

[0128] In the embodiment of floor component 300 utilized in the structure 150 of FIGS. 1A-5, floor beam assembly 325 is located at the mid-point between first transverse floor edge 120 and second transverse floor edge 118, and no hinge assemblies 329A are utilized elsewhere within floor component 300, such as proximate to first transverse floor edge 120 and second transverse floor edge 118. Therefore, to assist in smoothly rotating floor portion 300b, there is provided adjacent first transverse floor edge 120 a first floor end hinge assembly 345A joining floor portions 300a and 300b, and there is provided adjacent second transverse floor edge 118 a second floor end hinge assembly 345A joining floor portions 300a and 300b. The locations of both first and second floor end hinge assemblies 345A is indicated in FIG. 10. Floor end hinge assembly 345A comprises two identical floor end hinge portions 350A (not specified in the figures). A description of the construction of floor end hinge assembly 345A and its floor end hinge portions 350A is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled Folding Beam Systems, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled Folding Beam Systems, filed Nov. 16, 2021 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of floor end hinge assembly 345A and its floor end hinge portions 350A set forth for example in 0090-0093 and in FIGS. 14A-14B thereof.

[0129] D. Floor Component Manufacture

[0130] A floor component 300 comprises in substantial part two workpieces 250 joined by a floor beam assembly 325. In fabricating a floor component 300, each workpiece 250 is subject to the following steps: [0131] (1) Any electrical, plumbing or other utility access points are cut in workpiece 250 as desired. [0132] (2) The workpiece 250 is cut in the Y direction (see FIGS. 5 and 13) at the appropriate location (along line C in FIG. 13) to yield two workpiece portions 301 and 302. The transverse dimension of workpiece portion 301 (X direction in FIGS. 5 and 13) equals the transverse dimension of floor portion 300a, and the transverse dimension of workpiece portion 302 equals the transverse dimension of floor portion 300b. [0133] (3) Exterior and interior edge reinforcement, together with the desired sealing structures, are positioned and bonded to the interior and exterior edges of the workpiece portions 301 and 302. The edges of workpiece portions 301 and 302 to be joined to floor beam assembly 325 can be pre-cut at this point to conform to the profile of the beam assembly. [0134] (4) The workpiece portions 301 and 302 are painted. [0135] (5) The two workpieces 250 are then positioned as shown in FIG. 13, and joined to a floor beam assembly 325 to complete floor component 300.

[0136] Roof Component (400)

[0137] Typically, structure 150 will utilize one roof component 400; thus roof component 400 generally is the full roof of structure 150.

[0138] A. General Description

[0139] Roof component 400 has a generally rectangular perimeter and can be fabricated using one or more workpieces 250. FIG. 1B 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 FIGS. 1B, 4 and 5, the length and width of roof component 400 approximates the length and width of floor component 300.

[0140] B. Roof Partitioning

[0141] 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. 1B 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.

[0142] In the shipping module 15 shown in FIGS. 1A and 3, 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. As can be appreciated from FIG. 3, roof portion 400a is fixed in position relative to first wall portion 200s-1, third wall portion 200s-3 and wall component 200R. Thus to realize the accordion folded configuration shown in FIG. 3, 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. 1A and 3, where roof portion 400b lies stacked flat against roof portion 400a, and the fully unfolded position shown in FIG. 1B. In turn, 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 fully 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. 1B.

[0143] C. Hinged Vertical Load Transfer Components for Roof Component (400)

[0144] FIGS. 11A and 11B shows a roof beam assembly 425 that can be placed within roof component 400 to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne by floor component 300 to its edges. Roof beam assembly 425 includes three I-beams 426a, 426b and 426c. A hinge assembly 429B joins I-beam 426a to I-beam 426b. In addition, a hinge assembly 429C joins I-beam 426b to I-beam 426c. The hinge assemblies 429B and 429C permit roof beam assembly 425 to be folded to a beam folded position, shown in FIG. 11B, and unfolded to a beam unfolded position, shown in FIG. 11A. The I-beams 426a and 426b and 426c extend parallel to the transverse direction in the unfolded position. Further, the hinge assemblies 429B and 429C can be locked when roof beam assembly 425 is in the beam unfolded position, which transforms roof beam assembly 425 into a rigid structure that will reinforce roof component 400 in the direction perpendicular to its axes of folding.

[0145] Hinge assembly 429B comprises two identical hinge assembly portions 430B partnered together to form a pivoted junction, and hinge assembly 429C comprises two identical hinge assembly portions 430C partnered together to form a pivoted junction. A detailed description of the construction of these hinge assemblies and their hinge assembly portions is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled Folding Beam Systems, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled Folding Beam Systems, filed Nov. 16, 2021 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of hinge assembly 429B and its hinge assembly portions 430B set forth for example in 00106-00118 and in FIGS. 16-19 and 24A thereof, and the description of the construction of hinge assembly 429C and its hinge assembly portions 430C set forth for example in 00119-00126 and in FIGS. 20-23 and 24A-24B thereof.

[0146] In the embodiment of roof component 400 shown in the figures, roof beam assembly 425 is located at the mid-point between first transverse roof edge 408 and second transverse roof edge 410, and no hinge assemblies 429B or 429C are utilized elsewhere within roof component 400, such as proximate to first transverse roof edge 408 or second transverse roof edge 410. Therefore, to assist in smoothly rotating roof portion 400b relative to roof portion 400a, there is provided adjacent first transverse roof edge 408 a first roof end hinge assembly 445B joining roof portions 400a and 400b, and there is provided adjacent second transverse roof edge 410 a second roof end hinge assembly 445B joining roof portions 400a and 400b. Additionally, to assist in smoothly rotating roof portion 400c relative to roof portion 400b, there is provided adjacent first transverse roof edge 408 a first roof end hinge assembly 445C joining roof portions 400b and 400c, and there is provided adjacent second transverse roof edge 410 a second roof end hinge assembly 445C joining roof portions 400b and 400c. The locations of first and second roof end hinge assemblies 445B are indicated in FIG. 12, and the locations of first and second roof end hinge assemblies 445C are indicated in FIG. 12.

[0147] Roof end hinge assembly 445B comprises two identical roof end hinge portions 450B, and roof end hinge assembly 445C comprises two identical roof end hinge portions 450C (roof end hinge portions 450B, 450C are not specified in the figures). A description of the construction of these roof end hinge assemblies and roof end hinge portions is set forth in U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled Folding Beam Systems, filed Nov. 16, 2021 and having the same inventors as the subject application. The contents of that U.S. Non-Provisional patent application Ser. No. 17/527,520 entitled Folding Beam Systems, filed Nov. 16, 2021 and having the same inventors as the subject application, is incorporated by reference as if fully set forth herein, particularly the description of the construction of roof end hinge assembly 445B and its roof end hinge portions 450B set forth for example in 00127-00130 and in FIGS. 25A-25B thereof, and the description of the construction of roof end hinge assembly 445C and its roof end hinge portions 450C set forth for example in 00131-00132 and in FIGS. 24B and 25D thereof.

[0148] D. Roof Component Manufacture

[0149] A roof component 400 comprises in substantial part two workpieces 250 joined by a roof beam assembly 425. In fabricating a floor component 400, each workpiece 250 is subject to the following steps: [0150] (1) Any electrical, plumbing or other utility access points are cut in workpiece 250 as desired. [0151] (2) The workpiece 250 is cut in the Y direction (see FIGS. 5 and 14) at appropriate locations (along lines D.sub.1, and D.sub.2 in FIG. 14) to yield three workpiece portions 401, 402 and 403. The width of workpiece portion 401 (X direction in FIGS. 5 and 14) equals the width of roof portion 400a, the width of workpiece portion 402 equals the width of roof portion 400b and the width of workpiece portion 403 equals the width of roof portion 400c. [0152] (3) Exterior and interior edge reinforcement, together with the desired sealing structures, are positioned and bonded to the interior and exterior edges of the workpiece portions 401, 402 and 403. The edges of workpiece portions 401, 402 and 403 to be joined to roof beam assembly 425 can be pre-cut at this point to conform to the profile of the beam assembly. [0153] (4) The workpiece portions 401, 402 and 403 painted. [0154] (5) The two workpieces 250 are then positioned as shown in FIG. 14, and joined to a roof beam assembly 425 to complete roof component 400.

[0155] Optionally, roof beam assembly 425 can be provided with apertures as appropriate locations to permit communication between the vertical chases 219W in each of the two workpieces 250. As may be understood, through these apertures there runs a closed path or loop, utility service system 470, generally located about the periphery of roof component 400 and comprising, in addition to major portions of the vertical chases 219W, major portions of the horizontal chases 207 proximate the longitudinal and transverse edges of roof component 400. Utility service system 470 is a pathway through which utility trunk lines can be conveniently routed and connected to service lines, and also provides communication between the two utility service sub-systems 460 in the work pieces 250 of roof component 400.

Fixed Space Portion Build-Out and Finishing

[0156] Referring to FIG. 2, 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, 1B 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.

Enclosure Component Relationships and Assembly for Transport

[0157] It is preferred that there be a specific dimensional relationship among enclosure components 155.

[0158] Roof portions 400a, 400b and 400c each can be identically dimensioned in the transverse direction. Alternatively, referring to FIG. 3, 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 Ser. No. 17/569,962, entitled Improved Folding Roof Component, filed on Jan. 6, 2022. In addition, as described in U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled Equipment and Methods for Erecting a Transportable Foldable Building Structure, filed on Feb. 10, 2020 and now U.S. Pat. No. 11,220,816, as well as in U.S. Non-Provisional application Ser. No. 17/569,962 mentioned above, 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 corner 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 corner of roof portion 400c that is supported by wall portion 200s-4 as roof portion 400c is deployed.

[0159] Accordingly, in the preferred embodiment each of roof portions 400a and 400b is approximately 4E long and 1.25E wide, whereas roof portion 400c is approximately 4E long and 1.45E wide. In FIGS. 2 and 3, 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. Wall components 200P and 200R are approximately 4E long, whereas each of wall components 200s in the preferred embodiment is approximately 4E long, less the combined thicknesses of wall components 200P and 200R, as previously indicated.

[0160] As shown in FIG. 2, 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). The three roof components 400a, 400b and 400c are shown unfolded in FIG. 1B and shown folded (stacked) in FIGS. 1A and 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 (the general location of which is shown in FIG. 3), and is vertically positioned against the outside of wall portions 200s-2 and 200s-4. In turn, 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.

[0161] Sizing the enclosure components 155 of structure 150 according to the dimensional relationships disclosed above yields a compact shipping module 15, as can be seen from the figures. Thus shipping module 15 depicted in FIGS. 1A and 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.

[0162] 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 15. Alternatively or in addition, 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.

Shipping Module Transport

[0163] 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 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. Non-Provisional 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 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.

Structure Deployment and Finishing

[0164] At the building site, 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. 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. Particularly suitable equipment and techniques for facilitating the positioning of a shipping module 15 at the desired location are disclosed in U.S. Non-Provisional 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. Non-Provisional 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.

[0165] Following positioning of shipping module 15 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 FIG. 3) to an unfolded position, (2) wall component 200P is pivotally rotated about horizontal axis 105 (see FIG. 3) to an unfolded position, (3) wall portions 200s-2 and 200s-4 are pivotally rotated about vertical axes 192 and 194 (shown in FIG. 2) respectively to unfolded positions, and (4) roof portions 400b and 400c are pivotally rotated about horizontal axes 405a and 405b (shown in FIG. 3) respectively to unfolded positions.

[0166] After unfolding, the enclosure components 155 are secured together to finish the structure 150 that is shown in FIG. 1A. During or after unfolding and securing of the enclosure components 155, 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.

[0167] This disclosure should be understood to include (as illustrative and not limiting) the subject matter set forth in the following numbered clauses:

Clause 1. An enclosure component for a building structure, the enclosure component having [0168] a length, a width and a thickness and comprising: [0169] a first surface layer having a first face and an opposed second face; [0170] a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component; [0171] the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension; [0172] the second and third foam panels each having (a) an internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges; [0173] the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel; [0174] an elongate reinforcement spline in each recess; [0175] a second surface layer having a first face and an opposed second face; and [0176] the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer.
Clause 2. The enclosure component of clause 1, wherein the core layer further comprises: [0177] a planar rectangular fourth foam panel and a planar rectangular fifth foam panel, each of the fourth and fifth foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fourth and fifth foam panels being oriented along the length of the enclosure component; [0178] the fourth edge of the fourth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the fourth edge of the fifth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel; and [0179] the first and second edges of each of the fourth and fifth foam panels each has a same third linear dimension that is different from the first linear dimension.
Clause 3. The enclosure component of clause 2, wherein the third linear dimension is less than the first linear dimension.
Clause 4. The enclosure component of either clause 2 or clause 3, wherein the first edges of the first, second, third fourth and fifth foam panels are in aggregate equal to the length of the enclosure component.
Clause 5. The enclosure component of any one of clauses 1, 2, 3 or 4, wherein the third edge and the fourth edge of each of the first, second and third foam panels each equals the width of the enclosure component.
Clause 6. The enclosure component of claim 1, wherein the second and third foam panels are each symmetrical about a dividing line extending between the third and fourth edges and are each asymmetrical about a dividing line extending between the first and second edges.
Clause 7. The enclosure component of claim 1, wherein the internal passage of each of the second and third foam panels extends parallel to the recess and the internal passage and recess are offset from the fourth edge by an identical distance such that the internal passage and the recess are aligned within the thickness.
Clause 8. The enclosure component of claim 7, wherein the second and third foam panels include a further internal passage that is parallel to the recess and offset from the fourth edge a different distance than the recess.
Clause 9. The enclosure component of claim 1, wherein the internal passage in the first foam panel extends between the first and second edges midway between the third and fourth edges.
Clause 10. The enclosure component of claim 1, wherein one of the second or third foam panels is rotated one hundred eighty degrees relative to the other about an axis extending in a direction of the thickness that is perpendicular to the length and width.
Clause 11. The enclosure of component of claim 1, wherein each recess is formed on the second face of the core layer.
Clause 12. An enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising: [0180] a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component; [0181] a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component; [0182] the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension; [0183] the first and second edges of each of the first, second, third and fourth surface panels A each has a same third linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension; [0184] the second and third foam panels each having (a) a linear first internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges; [0185] the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel; [0186] the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A; [0187] an elongate reinforcement spline in each recess; [0188] a surface layer B having a first face and an opposed second face; and [0189] the second face of the surface layer A being bonded to the first face of the core layer, and the first face of the surface layer B being bonded to the second face of the core layer.
Clause 13. The enclosure component of clause 12, wherein the surface layer A further comprises: [0190] a planar rectangular fifth surface panel A and a planar rectangular sixth surface panel A, each of the fifth and sixth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fifth and sixth surface panels A being oriented along the length of the enclosure component; and [0191] the first and second edges of each of the fifth and sixth surface panels A each has a same fourth linear dimension that is different from the third linear dimension.
Clause 14. The enclosure component of clause 13, wherein the fourth linear dimension is less than the third linear dimension.
Clause 15. The enclosure component of either clause 13 or clause 14, wherein the first edges of the first, second, third, fourth, fifth and sixth surface panels A are in aggregate equal to the length of the enclosure component.
Clause 16. The enclosure component of any one of clauses 12, 13, 14 or 15, wherein the third edge of the first, second, third, fourth, fifth and sixth surface panels A each equals the width of the enclosure component.
Clause 17. The enclosure component of any one of clauses 12, 13, 14, 15 or 16, further comprising an elongate planar rectangular first joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the first joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge.
Clause 18. The enclosure component of clause 17, wherein the first joinder spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first joinder spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the first joinder spline being oriented along the length of the enclosure component, with each of the first and second edges of the first joinder spline having a linear dimension less than 50 percent of the third linear dimension.
Clause 19. The enclosure component of clause 18, wherein the first joinder spline is bonded to the first face of the core layer.
Clause 20. The enclosure component of either of clause 18 or clause 19, wherein the first and second edges of the first joinder spline have a linear dimension less than 25 percent of the third linear dimension.
Clause 21. The enclosure component of any one of clause 18, 19 or 20, wherein the first and second edges of the first joinder spline have a linear dimension less than 10 percent of the third linear dimension.
Clause 22. The enclosure component of any one of clauses 12-21, wherein the reinforcement spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the reinforcement spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the reinforcement spline being oriented along the length of the enclosure component, with each of the first and second edges of the reinforcement spline having a linear dimension less than fifty percent of the third linear dimension.
Clause 23. The enclosure component of clause 22, wherein the reinforcement spline is bonded to the core layer.
Clause 24. The enclosure component of either of clause 22 or clause 23, wherein the first and second edges of the reinforcement spline having a linear dimension less than 25 percent of the fourth linear dimension.
Clause 25. The enclosure component of any one of clause 22, 23 or 24, wherein the first and second edges of the reinforcement spline having a linear dimension less than 10 percent of the fourth linear dimension.
Clause 26. The enclosure component of any one of clauses 12-25, wherein the first joinder spline is steel.
Clause 27. The enclosure component of any one of clauses 12-26, wherein one or more of the surface panels A is cement board.
Clause 28. The enclosure component of any one of clauses 12-26, wherein the reinforcement spline is wooden.
Clause 29. The enclosure component of any one of clauses 12-28, wherein the surface layer B comprises: [0192] a planar rectangular first surface panel B and a planar rectangular second surface panel B, each of which has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, with the first and second edges being oriented along the length of the enclosure component; and [0193] the fourth edge of the first surface panel B arranged in a side-by-side relationship with the third edge of the second surface panel B.
Clause 30. The enclosure component of any one of clauses 12-29, further comprising an elongate planar rectangular second joinder spline overlapping the fourth edge of the first surface panel B and the third edge of the second surface panel B, the second joinder spline bonded to the first surface panel B proximate to its fourth edge and bonded to the second surface panel B proximate to its third edge.
Clause 31. The enclosure component of clause 30, wherein the second joinder spline is steel.
Clause 32. The enclosure component of any one of clauses 12-31, wherein the core layer includes a linear second internal passage parallel to the first internal passage, and a linear third internal passage parallel to the first internal passage, the first, second and third internal passages forming an internal passage array, the internal passages of which are spaced apart from each other by an integer multiple of a grid distance.
Clause 33. The enclosure component of clause 32, wherein the first surface layer includes a plurality of apertures proximate to an edge of the first surface layer that is along the length of the enclosure component, and the plurality of apertures are spaced apart from each other by one-half of an integer multiple of the grid distance.
Clause 34. The enclosure component of clause 33, wherein at least two of the plurality of apertures are bounded by at least two of the internal passages of the internal passage array, and each aperture of the at least two of the plurality of apertures is spaced apart from each passage of the at least two internal passages by an integer multiple of an offset distance.
Clause 35. The enclosure component of clause 34, wherein the offset distance is one-quarter the grid distance.
Clause 36. A foldable enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising: [0194] first and second enclosure component sub-portions, each such enclosure component sub-portion including: [0195] a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component; [0196] a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component; [0197] the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension; [0198] the first and second edges of each of the first, second, third and fourth surface panels A each has a same fourth linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension; [0199] the second and third foam panels each having an elongate recess on a surface of the panel spanning the distance between the first and second edges; [0200] the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel; [0201] the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A; [0202] an elongate reinforcement spline in each recess; [0203] an elongate planar rectangular joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge; [0204] a second surface layer having a first face and an opposed second face; and [0205] the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer; [0206] a beam assembly comprising a first beam joined to a second beam by a first hinge assembly defining a first hinge line; [0207] the first enclosure component sub-portion joined to the first beam and joined to the second beam; [0208] the second enclosure component sub-portion joined to the first beam and joined to the second beam; and [0209] the first enclosure component sub-portion divided along the first hinge line and the second enclosure sub-portion divided along the first hinge line to define a first enclosure component portion joined to the first beam and a second enclosure component portion joined to the second beam.
Clause 37. The foldable enclosure component of clause 36, wherein the beam assembly further comprises a third beam joined to the second beam by a second hinge assembly defining a second hinge line; [0210] the first enclosure component sub-portion is further joined to the third beam; [0211] the second enclosure component sub-portion is further joined to the third beam; and [0212] the first enclosure component sub-portion is further divided along the second hinge line and the second enclosure sub-portion is further divided along the second hinge line to define a third enclosure component portion joined to the third beam.
Clause 38. A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising: [0213] fabricating a first workpiece by performing at least the following steps: [0214] forming a first surface layer by arranging a plurality of planar rectangular first surface panels side-by-side to form one or more first seams between a respective one or more of the plurality of first surface panels; [0215] placing an elongate planar first joinder spline over one of the one or more first seams to form a first sub-assembly; [0216] forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel; [0217] forming a second surface layer by arranging a plurality of planar rectangular second surface panels side-by-side to form one or more second seams between a respective one or more of the plurality of second surface panels; [0218] placing a second elongate planar joinder spline over one of the one or more second seams to form a second sub-assembly; [0219] joining the first sub-assembly to the first face of the core layer; and [0220] joining the second sub-assembly to the second face of the core layer; [0221] thereby to fabricate the first workpiece.
Clause 39. A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising: [0222] fabricating a first workpiece by performing at least the following steps: [0223] placing at least two elongate planar rectangular first joinder splines spaced-apart a first select distance to form a first spline sub-assembly; [0224] forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel; [0225] joining the first spline sub-assembly to the first face of the core layer; [0226] placing at least two elongate planar rectangular second joinder splines spaced-apart a second select distance to form a second spline sub-assembly; [0227] joining the second spline sub-assembly to the second face of the core layer; [0228] forming a first surface layer by arranging three planar rectangular first surface panels side-by-side to provide a first middle panel flanked by a first pair of seams, where the first middle panel is dimensioned so that the first pair of seams is separated by the first select distance; [0229] joining the first surface layer to the first face of the core layer and the first spline sub-assembly positioned so that the first pair of seams overlie the first joinder splines; [0230] forming a second surface layer by arranging three planar rectangular second surface panels side-by-side to provide a second middle panel flanked by a second pair of seams, where the second middle panel is dimensioned so that the second pair of seams is separated by the second select distance; and [0231] joining the second surface layer to the second face of the core layer and the second spline sub-assembly positioned so that the second pair of seams overlie the second joinder splines; [0232] thereby to fabricate the first workpiece.
Clause 40. The method of either of clause 38 or clause 39, further comprising cutting an access point through the first surface layer to communicate with the internal passage.
Clause 41. The method of any one of clause 38, 39 or 40, further comprising cutting a door aperture or a window aperture through the workpiece.
Clause 42. The method of any one of clause 38, 39, 40 or 41, further comprising cutting the first workpiece parallel to the third edge of the first foam panel into two enclosure component portions.
Clause 43. The method of either of clause 38 or clause 39, further comprising: [0233] fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece; [0234] providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line; [0235] cutting the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular second enclosure component sub-portion; [0236] cutting the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular third enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular fourth enclosure component sub-portion; [0237] joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and [0238] joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.
Clause 44. The method of either of clause 38 or clause 39, further comprising: [0239] fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece; [0240] providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line, with a third beam having a third beam length joined to the second beam by a second hinge assembly defining a second hinge line; [0241] cutting in a first cutting step the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a first cut line from a planar rectangular second enclosure component sub-portion; [0242] cutting in a second cutting step the second enclosure component sub-portion parallel to the first cut line, and at a distance from a first cut line edge of the second enclosure component sub-portion equal to the second beam length, to form from the second enclosure component sub-portion a planar rectangular first enclosure component third sub-portion with a side having a linear dimension equal to the second beam length, separated along a second cut line from a planar rectangular fourth enclosure component sub-portion; [0243] cutting in a third cutting step the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular fifth enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a third cut line from a planar rectangular sixth enclosure component sub-portion; [0244] cutting in a fourth cutting step the sixth enclosure component sub-portion parallel to the third cut line, and at a distance from a third cut line edge of the sixth enclosure component sub-portion equal to the second beam length, to form from the sixth enclosure component sub-portion a planar rectangular enclosure component seventh sub-portion with a side having a linear dimension equal to the second beam length, separated along a fourth cut line from a planar rectangular eighth enclosure component sub-portion; [0245] joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and [0246] joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.
Clause 45. A foldable enclosure component for a building structure, the enclosure component comprising: [0247] a floor component formed by: [0248] two of the enclosure components as recited in any one of clauses 1-11 or any one of clauses 12-35; and [0249] a first beam assembly positioned between and joined to the enclosure components of the floor component, the first beam assembly including a first beam and a second beam attached to the first beam by a first hinge to define a first hinge line along which the enclosure components are cut to define a first portion of the floor component and a second portion of the floor component pivotally joined to each other by the first hinge to allow the floor component to move between a folded position and an unfolded position; and [0250] a ceiling component formed by: [0251] two of the enclosure components as recited in any one of clauses 1-11 or any one of clauses 12-35; [0252] a second beam assembly positioned between and joined to the enclosure components of the ceiling component, the second beam assembly including a first beam, a second beam attached to the first beam by a first hinge to define a first hinge line, and a third beam attached to the second beam by a second hinge to define a second hinge line, the enclosure components of the ceiling component are cut to along the first and second hinge lines of the second beam assembly to define a first portion of the ceiling component, a second portion of the ceiling component pivotally joined to the first portion of the ceiling component by the first hinge, and a third portion of the ceiling component pivotally joined to the second portion of the ceiling component by the second hinge to allow the ceiling component to move between a folded position and an unfolded position.

[0253] 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.