Surrounding structure of enclosure components

Abstract

An enclosure element for an architectural structure includes a planar laminate having a first surface layer, a foam layer having a first surface and an opposite second surface, and a second surface layer, the first surface layer being bonded to the first surface of the foam layer and the second surface layer being bonded to the opposite second surface of the foam layer. According to certain embodiments, the edges of the enclosure are provided with a peripheral structure that can perform one or more of the following functions: sealing, edge reinforcement, and pivotal connection with another enclosure.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 805,710, filed February 14, 2019, and U.S. Provisional Patent Application No. 62 / 960,991, filed January 14, 2020.

[0002] The present invention relates to structures, such as dwellings and other buildings for residential occupancy, commercial occupancy and / or material storage, and components of such structures. [Background technology]

[0003] In the realm of housing complexes, the traditional technique for building a home is called "stick-built" construction, where builders construct a home at its intended location using mostly raw materials such as wooden boards, plywood panels, and steel Lally columns. The materials are assembled piece by piece over a pre-prepared portion of the ground, such as a cast-in-place concrete slab, or a cast-in-place concrete or cinder block foundation.

[0004] There have been many attempts to move away from traditional construction techniques used to create residential and commercial spaces and the like. One of the alternatives to prefabricated construction is most commonly referred to as modular housing. Unlike prefabricated construction, where the structure is erected on-site, modular homes are constructed in a factory and then shipped to the site, often using a tractor trailer. A drawback of modular housing is that the structure layout can only be customized to a relatively limited extent by the prospective buyer. That is, while certain features, such as a closet, can be added or removed from a room, the overall shape and layout of the home cannot be altered or adapted to the customer's preferences.

[0005] In addition, modular housings often exceed the legal size limits normally permitted for road transportation. For example, in the United States, the maximum allowable dimensions for road transportation are typically 102 inches (259.1 cm) in width, 13.5 feet (4.11 m) in height, and 65 feet to 75 feet (19.81 m to 22.86 m) in length. Thus, oversize load permits are often required to transport modular homes from the factory to the site, which may impose restrictions on the time that transportation can be undertaken and the route that can be utilized. Oversize road regulations may also require the use of escort and trailer vehicles. All of these requirements and restrictions necessarily increase the cost of modular housing.

[0006] Significant advances in the construction of residential and commercial spaces are described in U.S. Patent Nos. 5,233,633, 5,293,322 and 5,363,666. In one form, these patents relate to the manufacture in a factory of wall, floor and ceiling members that fold together into compact shipping modules and are then transported to the intended location and unfolded to provide a structure, where folding and unfolding of the members can be facilitated by the use of hinges. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Patent No. 8,474,194 [Patent Document 2] U.S. Patent No. 8,733,029 [Patent Document 3] US Patent Application Publication No. 2019 / 0100908 Summary of the Invention

[0008] The present invention relates to perimeter structures of enclosure members that include hinged structures that can be left in place after delivery, thereby reducing on-site assembly costs. In addition, the hinged and other perimeter structures of enclosure members described herein can function as load-bearing structural members and can also contribute to the weather resistance of the enclosure members to which they are secured. The present invention facilitates the provision of enclosure members and enclosure member portions that can be compactly packaged for easy shipment from a factory to a construction site, and that are joined together to enable rapid field-level deployment with factory-level tolerances and repeatability.

[0009] In one form, the invention relates to a reinforced enclosure member for an architectural structure comprising: a planar laminate having generally straight edges having a first surface layer, a foam layer having a first side and an opposite second side, and a second surface layer, the first surface layer being attached to the first side of the foam layer and the second surface layer being attached to the opposite second side of the foam layer; and a reinforced end cap comprising a first elongated flange surface joined to the elongated web surface at a first joint and a second elongated flange surface joined to the elongated web surface at a second joint, the first elongated flange surface and the second elongated flange surface being spaced apart a predetermined distance, the web surface, the first elongated flange surface and the second elongated flange surface generally forming a C-channel shape. An elongated cavity wall is provided joined to each of the first and second elongated flange surfaces, the elongated cavity wall being spaced from and generally parallel to the elongated web surface, extending a distance separating the first and second elongated flange surfaces and defining a reinforcing channel within which a filler reinforcement is provided. A reinforcing end cap is secured to the generally straight edge of the planar laminate, the distance separating the first and second elongated flange surfaces being adapted to receive at least the generally straight edge of the foam layer therebetween.

[0010] In another form, the invention relates to a collapsible enclosure member for an architectural structure comprising a first planar laminate having a first generally straight edge and a second planar laminate having a second generally straight edge, each planar laminate having a first surface layer, a foam layer having a first face and an opposite second face, and a second surface layer, the first surface layer affixed to the first face of the foam layer and the second surface layer affixed to the opposite second face of the foam layer. The collapsible enclosure member further comprises a first peripheral section including a first elongated web surface having a first elongated edge region and a second elongated edge region, and a second peripheral section including a third elongated edge region and a fourth elongated edge region. The first peripheral section is secured to a generally straight edge of the first planar laminate and the second peripheral section is secured to a generally straight edge of the second planar laminate, the first peripheral section having a first series of hinge knuckles proximate the first elongated edge region and a second series of hinge knuckles proximate the second elongated edge region, and the second peripheral section having a third series of hinge knuckles proximate the third elongated edge region and a fourth series of hinge knuckles proximate the fourth elongated edge region. The first series of hinge knuckles mate with the third series of hinge knuckles, a first rod is housed in the mated first and third series of hinge knuckles, and the mated first and third series of hinge knuckles join to form a pivotable joint between the first and second peripheral sections, the pivotable joint being pivotable from a folded position in which the first elongated web surface is oriented at an angle relative to the second elongated web surface to an unfolded position in which the first elongated web surface is in flush contact with the second elongated web surface. The second series of hinge knuckles are adapted to mate with the fourth series of hinge knuckles when the pivotable joint is in the unfolded position.The foldable enclosure members also include a second rod, and the second series of hinge knuckles and the fourth series of hinge knuckles are adapted to house the second rod when interlocked and form a rigid structure between the first and second peripheral sections, the rigid structure including the first and second peripheral sections.

[0011] These and other aspects of the present invention are illustrated in the drawings attached hereto and in the preferred embodiments and claims described below. [Brief description of the drawings]

[0012] [Figure 1A] FIG. 1 is a perspective view of a completed structure prepared in accordance with the present invention. [Figure 1B] FIG. 1 is a perspective view of a completed structure prepared in accordance with the present invention. [Figure 2A] FIG. 2 is a schematic top view of a completed structure prepared in accordance with the present invention. [Figure 2B] FIG. 2 is a schematic top view of a completed structure prepared in accordance with the present invention. [Figure 3A] FIG. 1B is an end view of the shipping module from which the finished structure shown in FIG. 1A is formed. [Figure 3B] FIG. 1C is an end view of the shipping module from which the finished structure shown in FIG. 1B is formed. [Figure 4A] FIG. 2 is an exploded cross-sectional view of one embodiment of a laminated multi-layer structure for use in the enclosure member of the present invention. [Figure 4B] FIG. 2 is an exploded cross-sectional view of one embodiment of a laminated multi-layer structure for use in the enclosure member of the present invention. [Figure 4C] FIG. 2 is an exploded cross-sectional view of one embodiment of a laminated multi-layer structure for use in the enclosure member of the present invention. [Figure 4D] FIG. 2 is an exploded cross-sectional view of one embodiment of a laminated multi-layer structure for use in the enclosure member of the present invention. [Figure 5A]FIG. 2 is a cutaway perspective internal view of a wall member according to the present invention. [Figure 5B] FIG. 2 is a cutaway perspective external view of a wall member according to the present invention. [Figure 6A] FIG. 2 is a partially cutaway perspective view of a completed structure according to the present invention, showing in more detail the configuration of the ceiling members, wall members and floor members of the first type of structure according to the present invention; [Figure 6B] FIG. 2 is a partially cutaway perspective view of a completed structure according to the present invention, showing in more detail the configuration of the ceiling members, wall members and floor members of the first type of structure according to the present invention; [Figure 7A] FIG. 2 is a partial cutaway view of a completed structure according to the present invention, showing in more detail the configuration of the ceiling, wall and floor members of a second type of structure according to the present invention; [Figure 7B] FIG. 2 is a partial cutaway view of a completed structure according to the present invention, showing in more detail the configuration of the ceiling, wall and floor members of a second type of structure according to the present invention; [Figure 8] FIG. 2 is a schematic side view of one embodiment of a hinge structure joining two floor sections according to the present invention. [Figure 9] FIG. 2 is a schematic side view of one embodiment of a hinge structure for joining two roof sections according to the present invention. [Figure 10] FIG. 2 is a side view of an independent end cap according to the present invention. [Figure 11] FIG. 2 is a side view of a reinforced end cap according to the present invention. [Figure 12] FIG. 2 is a side view of an abutting end cap according to the present invention. [Figure 13A] FIG. 2 is a side view of a first hinged I-beam structure according to the present invention. [Figure 13B] FIG. 2 is a side view of a first hinged I-beam structure according to the present invention. [Figure 13C] FIG. 2 is a side view of a first hinged I-beam structure according to the present invention. [Figure 13D] FIG. 2 is a perspective view of a peripheral section of a first hinged I-beam structure according to the present invention. [Figure 13E]FIG. 2 is a perspective view of a first hinged I-beam structure according to the present invention. [Figure 13F] FIG. 2 is a perspective view of a first hinged I-beam structure according to the present invention. [Figure 14A] FIG. 11 is a side view of a second hinged I-beam structure according to the present invention. [Figure 14B] FIG. 11 is a side view of a second hinged I-beam structure according to the present invention. [Figure 14C] FIG. 11 is a side view of a second hinged I-beam structure according to the present invention. [Figure 14D] FIG. 11 is a side view of a second hinged I-beam structure according to the present invention. [Figure 14E] FIG. 13 is a perspective view of a second hinged I-beam structure according to the present invention. [Figure 14F] FIG. 13 is a perspective view of a second hinged I-beam structure according to the present invention. [Figure 15] FIG. 2 is a side view of a tongue and groove hinge structure according to the present invention. [Figure 16] FIG. 2 is an exploded perspective view of a completed structure according to the present invention showing the proper location of the peripheral structures of the enclosure members of the present invention; [Figure 17] FIG. 1 is a perspective view of an enclosure member and its abutting end cap prepared in accordance with the present invention, showing openings in the structural layer for receiving fasteners. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] FIG. 1A illustrates a first type of completed structure 150 (sometimes referred to herein as Type 1 structure 151) in accordance with the present invention disclosed herein, and FIG. 1B illustrates a second type of completed structure 150 (sometimes referred to herein as Type 2 structure 152) in accordance with the present invention disclosed herein. Although Type 1 structure 151 is smaller than Type 2 structure 152, the invention described herein is equally applicable to the manufacture and deployment of Type 1 structure 151, Type 2 structure 152, and other structures of different dimensions. Thus, when reference is made herein to "structure 150," it should be understood to refer collectively to Type 1 structure 151 and Type 2 structure 152 without distinction. Similarly, when reference is made in this disclosure to components identified with the same reference numerals between different embodiments, it indicates that such components are the same between such different embodiments.

[0014] 1A and 1B has a rectangular shape made up of three types of generally planar and rectangular enclosure members 155 consisting of wall members 200, floor members 300, and ceiling members 400. The structure 150 has one floor member 300, one ceiling member 400, and four wall members 200. As shown in FIGS. 1A and 1B, the perimeter of the completed structure 150 is defined by a first longitudinal edge 106, a first lateral edge 108, a second longitudinal edge 116, and a second lateral edge 110.

[0015] The enclosure members 155 (wall members 200, floor members 300, and ceiling members 400) can be manufactured and sized as described herein and positioned together to form a shipping module 100, as shown end-on in FIGS. 3A and 3B, where FIG. 3A shows the shipping module 100 for a Type 1 structure 151 and FIG. 3B shows the shipping module 100 for a Type 2 structure 152. The enclosure members 155 are sized so that the shipping module 100 fits within U.S. Federal highway dimensional limits. As a result, the shipping module 100 can be more easily transported through restricted access highways and can be transported without the need for an oversized load permit using appropriate trailer equipment. Thus, the foundation members of the completed structure 150 can be manufactured in a factory and positioned together to form a shipping module 100, as described herein, and the module 100 can be transported to a desired site for the structure where it can be easily assembled and customized.

[0016] Stacking design of enclosure components A laminated multi-layer design can be used to manufacture the enclosure member 155 of the present invention. Figures 4A-4D show four embodiments of such a multi-layer design for an exemplary enclosure member 155 in exploded cross-sectional views.

[0017] First and second embodiments Internal coating layer (282) In first and second embodiments of a laminated multi-layer design, shown in Figures 4A and 4B, respectively, the surface of the enclosure member 155 facing towards the interior of the structure 150 is optionally provided with an inner cover layer 282. The inner cover layer 282 is preferably manufactured from a relatively thick paper, of a weight similar to that used as the exterior surface of drywall (e.g., sold under the trade name Sheetrock™). The inner cover layer 282 is preferably unwound from a continuous roll of paper (the paper roll having a width approximating the width of the enclosure member 155, if desired) to provide a seamless interior finish for the enclosure member 155.

[0018] First structural layer (210) A first structural layer 210 is provided in the first embodiment shown in FIG. 4A and in the second embodiment shown in FIG. 4B. When used, the inner cover layer 282 is adhered to this first structural layer 210 using a suitable adhesive, preferably a polyurethane-based construction adhesive. The first structural layer 210 in the illustrated embodiment includes a plurality of rectangular structural building panels 211 that are essentially comprised of a relatively high strength inorganic composition, such as magnesium oxide (MgO). A suitable structural building panel 211 may be an MgO board approximately 4 feet (1.22 m) wide by approximately 8 feet (2.44 m) long. In a particular embodiment of the first embodiment of the multi-layer design of FIG. 4A, the thickness of those structural building panels 211 that use magnesium oxide boards may be approximately 0.5 inches (1.27 cm), or alternatively, a thickness of approximately 0.25 inches (0.64 cm) may be employed.

[0019] To form the first structural layer 210, a plurality of generally rectangular structural building panels 211 are positioned adjacent to one another to generally cover the entire area of ​​the intended enclosure member 155. For example, for the wall member 200a shown in Figure 5A, the structural building panels 211 are positioned horizontally and vertically adjacent to one another in a checkerboard relationship to generally cover the entire area of ​​the wall member 200a. As another exemplary arrangement, a plurality of structural building panels 211 of sufficient length can be positioned side by side vertically to generally cover the entire area of ​​the wall member 200.

[0020] The first structural layer 210 in the first and second embodiments shown in Figures 4A and 4B, respectively, further comprises a plurality of joining strips 212, made for example from magnesium oxide boards, arranged both horizontally and / or vertically as appropriate. In particular, the joining strips 212 are positioned across the linear joints between adjacent panels 211 and then secured, for example using a suitable adhesive, preferably a polyurethane-based construction adhesive, to the areas of those panels that border those joints to form a lap joint between the adjacent building panels 211, thereby bonding the panels 211 of the first structural layer 210 together to form a single unit. The joining strips 212 of magnesium oxide boards may be, for example, approximately 6 inches (15.2 cm) wide and 0.25 inches (0.635 cm) or 0.5 inches (1.27 cm) thick.

[0021] First Reinforcement Layer (213-1) As shown in the first and second embodiments shown in Figures 4A and 4B, respectively, a first reinforcing layer 213-1 is then provided, which is made from a fiber fabric, such as a woven glass fiber fabric. In the first embodiment shown in Figure 4A, the first reinforcing layer 213-1 is preferably unwound from a continuous mat roll (the mat roll having a width approximating the width of the enclosure member 155, if desired), resulting in a seamless inner layer. In the second embodiment shown in Figure 4B, the first reinforcing layer 213-1 includes a plurality of separate fiber layer segments, as illustrated by segments 213-1a and 231-1b shown in Figure 4B, positioned between the connecting strips 212.

[0022] Foam Panels(214) 4A and 4B, a plurality of generally planar rectangular foam panels 214 are then provided that collectively form a first surface and an opposite second surface in the first and second embodiments. The foam panels 214 are made, for example, from expanded polystyrene (EPS) or polyurethane foam. A plurality of these foam panels 214 are positioned adjacent to one another to generally cover the entire area of ​​the intended enclosure member 155. For example, for the wall member 200a shown in FIG. 5B, the foam panels 214 are positioned horizontally and vertically adjacent to one another in a checkerboard relationship to generally cover the entire area of ​​the wall member 200a. As another exemplary arrangement, a plurality of foam panels 214 of sufficient length can be positioned side by side and vertically to generally cover the entire area of ​​the wall member 200.

[0023] The seams between adjacent foam panels 214 preferably do not overlap or coincide with the seams between the structural building panels 211 of the first structural layer 210 across the thickness of the enclosure member 155. Rather, the seams between adjacent foam panels 214 are preferably offset a predetermined distance from the seams between adjacent structural building panels 211 of the first structural layer 210. For example, for both laterally and vertically positioned foam panels 214 and laterally and vertically positioned structural building panels 211, the seams between adjacent foam panels may be positioned at the centerlines (center demarcation lines) of the structural building panels 211 or as close to the centerlines of the structural building panels 211 as design, manufacturing, and other considerations permit. Correspondingly, with the foam panels 214 arranged in a checkerboard relationship and the structural building panels 211 arranged in a checkerboard relationship, each corner where the four foam panels 214 meet can be positioned at the center of the structural building panel 211 or as close to the center of the structural building panel 211 as design, manufacturing and other considerations will permit.

[0024] The first reinforcing layer 213-1 is preferably sandwiched between both the first structural layer 210 and the first surface of the foam panel 214 and secured to both using a suitable adhesive, preferably a polyurethane-based construction adhesive. If the fiber fabric of the first reinforcing layer 213-1 has a relatively open weave, only one application of adhesive during manufacture is required to bond the layers 210, 213-1 and 214 together into a bonded laminated structure. Adjacent foam panels 214 can be secured to one another, if desired, by applying a suitable adhesive, preferably a polyurethane-based construction adhesive, between the abutting panels.

[0025] Second Reinforcement Layer (213-2) In a first embodiment of the laminated multi-layer design shown in Figure 4A, a first reinforcing layer 213-1, which is a reinforcing layer of woven fiber fabric, is present on only one side of the foam panel 214. In a second embodiment of the laminated multi-layer design shown in Figure 4B, a second reinforcing layer 213-2, made of a woven fiber fabric, such as woven glass fiber fabric, is present on a second, opposite side of the foam panel 214. The second reinforcing layer 213-2 can be continuous, like the first reinforcing layer 213-1 shown in Figure 4A, or can include multiple separate fiber layer segments, as exemplified by segments 213-2a and 231-2b shown in Figure 4B, positioned between connecting strips 217, as will be further described below.

[0026] Second structural layer (215) In a first embodiment of the laminated multi-layer design shown in FIG. 4A, a second structural layer 215 is provided and positioned on the opposite second surface of the foam panel 214 (the surface distal from the first structural layer 210). In a second embodiment of the laminated multi-layer design shown in FIG. 4B, a second structural layer 215 is similarly provided, but in this second embodiment, a second reinforcing layer 213-2 is sandwiched between the opposite second surface of the foam panel 214 and the second structural layer 215. The second structural layer 215 includes a plurality of rectangular structural building panels 216, each of which is essentially comprised of a relatively high strength inorganic composition, such as magnesium oxide. A suitable building panel 216 may be a magnesium oxide board approximately 4 feet (1.22 m) wide by approximately 8 feet (2.44 m) long. In an exemplary embodiment of the second structural layer 215, those structural building panels 216 using magnesium oxide boards may have a thickness of approximately 0.5 inches (1.27 cm), while other forms may employ a thickness of approximately 0.25 inches (0.64 cm).

[0027] To form the second structural layer 215, a plurality of rectangular structural building panels 216 are positioned adjacent to one another to generally cover the entire area of ​​the intended enclosure member 155. For example, for the wall member 200a shown in FIG. 5B, the structural building panels 216 are positioned horizontally and vertically adjacent to one another in a checkerboard relationship to generally cover the entire area of ​​the wall member 200a. As another exemplary arrangement, a plurality of structural building panels 216 of sufficient length may be positioned side-by-side and vertically to generally cover the entire area of ​​the wall member 200.

[0028] As with the first structural layer 210, the seams between adjacent foam panels 214 preferably do not overlap or coincide with the seams between the structural building panels 216 of the second structural layer 215 in a direction across the thickness of the enclosure member 155. Rather, the seams between adjacent foam panels 214 are preferably offset a predetermined distance from the seams between adjacent structural building panels 216 of the second structural layer 215. For example, for both laterally and vertically positioned foam panels 214 and laterally and vertically positioned structural building panels 216, the seams between adjacent foam panels 214 may be positioned at or as close to the centerlines of the structural building panels 216 as design, manufacturing, and other considerations permit. Correspondingly, with the foam panels 214 arranged in a checkerboard relationship and the structural building panels 216 arranged in a checkerboard relationship, each corner where the four foam panels 214 meet can be positioned at or as close to the center of the structural building panel 216 as design, manufacturing and other considerations will permit. On the other hand, the seams between the structural building panels 211 of the first structural layer 210 can be coincident with the seams of the structural building panels 216 of the second structural layer 215 in a direction across the thickness of the enclosure member 155, or either way.

[0029] The second structural layer 215 in the first and second embodiments shown in Figures 4A and 4B, respectively, further comprises a plurality of bonding strips 217, made for example from magnesium oxide board, positioned between the building panels 216 and the foam panels 214. The bonding strips 217 are positioned across the linear joints between adjacent panels 216 and then secured, for example using a suitable adhesive, preferably a polyurethane-based construction adhesive, to the areas of those panels that border those joints to form a lap joint between the adjacent building panels 216, thereby bonding the panels 211 of the first structural layer 210 together to form a single unit. The magnesium oxide board bonding strips 217 can be, for example, approximately 6 inches (15.2 cm) wide and 0.25 inches (0.635 cm) or 0.5 inches (1.27 cm) thick.

[0030] If the first reinforcing layer 213-1 and / or the second reinforcing layer 213-2 are formed from a continuous roll, the foam panel 214 may be provided with suitable recesses (not shown) to accommodate local thickness variations of the layer 213-1 / bonding strip 212 and / or layer 213-2 / bonding strip 217 combinations, such as may occur in areas proximate the bonding strips. If the first reinforcing layer 213-1 and / or the second reinforcing layer 213-2 are formed from separate segments, the foam panel 214 may be provided with suitable recesses (not shown) to receive the bonding strips 212 and / or 217.

[0031] In a first embodiment shown in Figure 4A, the second structural layer 215 is secured to the foam panel 214, for example using a suitable adhesive, preferably a polyurethane-based construction adhesive. In a second embodiment shown in Figure 4B, the second reinforcing layer 213-2 is preferably secured to both the second structural layer 215 and the foam panel 214, for example using a suitable adhesive, preferably a polyurethane-based construction adhesive. If the fiber weave of the second reinforcing layer 213-2 has a relatively open weave, only one adhesive application is needed during manufacture to bond the layers 214, 213-2 and 215 together into a bonded laminated structure.

[0032] In the embodiment of wall member 200 shown in Figure 5B, the outer surface of the structural building panels 216 of the second structural layer 215 are provided with grooves 218 for aesthetic reasons, in particular to better hide the presence of seams between adjacent panels 216. It should be noted that the outer surface of the panels 216 may be covered with an additional protective material unwound from a continuous roll.

[0033] Reinforcing layer 213-1 and / or reinforcing layer 213-2 may be omitted if there is no tensile loading in that region. Additionally, although inner coating layer 282 is shown adhered to first structural layer 210, inner coating layer 282 could just as easily be adhered to second structural layer 215, where that structural layer faces the interior, occupied portion of the structure. Inner coating layer 282 may also be omitted if not desired.

[0034] Third and fourth embodiments A third embodiment of a laminated multi-layer design is shown in Fig. 4C. Compared to the second embodiment shown in Fig. 4B, the third embodiment of Fig. 4C has a sheet metal layer 205 instead of the second structural layer 215, but is otherwise of the same design as the second embodiment shown in Fig. 4B. The sheet metal layer 205, which can be, for example, steel or aluminum, is made of a number of generally planar rectangular metal sheets 206 positioned adjacent to each other to generally cover the entire area of ​​the intended enclosure member 155 and joined together, such as by riveting or welding. After joining, the joined metal sheets 206 of the sheet metal layer 205 are secured to the opposite second side of the foam panel 214 (the side of the foam panel 214 distal from the structural layer 210) by a suitable adhesive application.

[0035] Preferably, the seams between adjacent foam panels 214 do not overlap or coincide with the seams in the bonded metal sheets 206 of the sheet metal layer 205 in a direction across the thickness of the enclosure member 155. Rather, the seams between adjacent foam panels 214 are preferably offset a predetermined distance from the seams in the bonded metal sheets 206 of the sheet metal layer 205. For example, for laterally and vertically positioned foam panels 214 and laterally and vertically positioned bonded metal sheets 206, the seams between adjacent foam panels can be positioned at the centerlines (center demarcation lines) of the bonded metal sheets 206 or as close to the centerlines of the bonded metal sheets 206 as design, manufacturing, and other considerations will permit.

[0036] In this third embodiment, the metal sheets 206 of the sheet metal layer 205 may be made of steel, with protective and / or decorative surface treatments as required, each having a thickness, for example, in the range of approximately 26 gauge to 20 gauge (0.0179 inches (0.454 mm) to 0.0478 inches (1.214 mm)). The use of the sheet metal layer 205 provides increased tensile strength, for example, compared to the structural building panel 216, particularly the second structural layer 215 comprising magnesium oxide board. At the same time, the laminated multi-layer design shown in FIG. 4C provides substantial compressive strength in the region of the structural building panel 211, particularly the first structural layer 210 comprising magnesium oxide board.

[0037] A fourth embodiment of the laminated multi-layer design is shown in Fig. 4D. In comparison with the third embodiment shown in Fig. 4C, the fourth embodiment of Fig. 4D has a protective layer 293 interposed between the foam panel 214 and the sheet metal layer 205, but is otherwise identical in design to the third embodiment shown in Fig. 4C. The protective layer 293 includes a plurality of generally rectangular protective panels 294 arranged adjacent to each other to generally cover the entire area of ​​the intended enclosure member 155. The protective panels 294 of the protective layer 293 can essentially include fire-resistant inorganic compositions such as magnesium oxide (MgO) or calcium sulfate dihydrate (also known as drywall and marketed, for example, under the trademark Sheetrock™). A suitable protective panel 294 for the protective layer 293 can be a magnesium oxide board approximately 4 feet (1.22 m) wide by approximately 8 feet (2.44 m) long.

[0038] The protective building panel 294 of the protective layer 293 is adhered to both the foam panel 214 and the sheet metal layer 205 with an appropriate adhesive coating applied between the protective layer 293 and the second, opposite side of the foam panel 214 and between the protective layer 293 and the sheet metal layer 205. A suitable thickness for the protective building panel 294 of the protective layer 293 using magnesium oxide board may be 0.125 inches (3.18 mm). The primary function of the protective layer 293 in the fourth embodiment of the laminated multi-layer structure shown in FIG. 4D is to provide fire resistance.

[0039] Enclosure member outer edge reinforcement An edge stiffener may be provided at the outer edge defining the perimeter of each enclosure member (or enclosure component) 155, if desired. The edge stiffener may protect the foam panel material that would otherwise be exposed at the outer edge of the enclosure member 155. The edge stiffener may also serve other functions, as described below. The edge stiffener may be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, and the like, and is typically secured to the outer edge of the enclosure member 155 using fasteners, such as screws or nail fasteners, and / or adhesives.

[0040] Sectioning of enclosure components The enclosure member 155 in certain instances is segmented or partitioned into enclosure member portions to facilitate the formation of a compact shipping module 100. In those instances where the enclosure member 155 is segmented into enclosure member portions, any outer edge reinforcements at the outer edge defining the perimeter of the enclosure member are split between two or more of those portions, as necessary.

[0041] Enclosure member inner edge reinforcement The enclosure member 155, segmented into enclosure member portions, will have an inner edge. For each adjacent pair of enclosure member portions, there will be two adjacent inner edges. Such inner edges may be provided with an inner edge stiffener. Like the outer edge stiffener, such inner edge stiffener may protect the foam panel material that would otherwise be exposed at the inner edge of the enclosure member 155. The inner edge stiffener may also serve other functions as described below. The inner edge stiffener may be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, and the like, and is typically secured to the inner edge of the enclosure member 155 using fasteners, such as screws or nail fasteners, and / or adhesives.

[0042] Further design details of the completed structure 150, wall members 200, floor members 300, and ceiling members 400 are provided in the following sections.

[0043] Wall parts (200) Typically, a completed structure 150 utilizes four wall members 200, with each wall member 200 corresponding to an entire wall of the structure 150. The wall members 200 have a generally rectangular perimeter. The height and length of the wall members 200 can be varied according to design preferences, subject to the dimensional limitations applicable to shipping as discussed above. In this disclosure, when the structure 150 is made with two opposing sides longer than the other two sides (as in the case of the Type 1 structure 151), the two wall members 200 positioned along the first longitudinal edge 106 and the second longitudinal edge 116 may be referred to as long wall members, and are designated 200a, respectively, and the two wall members 200 positioned along the first lateral edge 108 and the second lateral edge 110 may be referred to as short wall members, and are designated 200b, respectively. When structure 150 is made with all sides approximately equal in length (as is the case for Type 2 structure 152), each of the four wall members 200 may be referred to as 200s. The basic structure and design of wall members 200 is the same for both Type 1 structure 151 and Type 2 structure 152 and is applicable to structures 150 in general.

[0044] In the particular embodiment of the Type 1 structure 151 shown in Figures 1A and 2A, the long wall member 200a is approximately 39 feet (11.89 m) long and the short wall member 200b is approximately 19.5 feet (5.94 m) long. Thus, the long wall member 200a positioned along the first longitudinal edge 106 and the second longitudinal edge 116 is approximately twice as long as the short wall member 200b positioned along the first lateral edge 108 and the second lateral edge 110. The long wall member 200a and the short wall member 200b are approximately 9.5 feet (2.9 m) high and approximately 6 inches (15.24 cm) thick.

[0045] As noted above, the Type 2 structure 152 shown in Figures 1B and 2B has wall members 200, 200s of equal length (respectively referred to as 200s). That is, the Type 2 structure 152 has a generally square shape. Thus, for the Type 2 structure 152, the first and second longitudinal edges 106, 116, and the first and second lateral edges 108, 110 are all equal in length. In the particular embodiment of the Type 2 structure 152 shown in Figures 1B and 2B, the wall members 200, 200s may be approximately 19 feet (5.79 m) long, approximately 9.45 feet (2.88 m) high, and approximately 6 inches (15.24 cm) thick.

[0046] As indicated above, the wall member 200 of the present invention preferably utilizes one of the laminated multi-layer designs described above with reference to Figures 4A-4D. For example, the long wall member 200a shown in Figures 5A and 5B may utilize the second embodiment of the laminated multi-layer design described above with reference to Figure 4B. The particular embodiment of the wall member 200s of the Type 2 structure 152 shown in Figures 1B and 2B referred to above may utilize the second multi-layer design (Figure 4B) in which the structural building panel 211 of the first structural layer 210 and also the structural building panel 216 of the second structural layer 215 are 0.25 inch (0.635 cm) thick MgO boards, and the joining strips 212, 217 are 0.25 inch (0.635 cm) thick MgO boards and are 6 inches (15.24 cm) wide. The foam panel 214 may be 5.5 inches (13.97 cm) thick, making the wall member 200 approximately 6 inches (15.24 cm) thick.

[0047] An outer edge reinforcement is typically provided around the perimeter of each wall member 200. As illustrated by the long wall member 200a shown in Figure 5A, the outer edge reinforcement of the wall member 200 is a floor board 220 along the horizontal bottom edge, a ceiling board 240 along the horizontal top edge, and two end pieces 270 that are fastened to each vertical edge 275 of the wall member 200, respectively. In the case of the wall member 200, the outer edge reinforcement, in addition to protecting the outer edges of the foam panel material, provides areas for fastening similar areas of the abutting wall member 200, ceiling member 400, and floor member 300.

[0048] The outer edge reinforcement of the wall member 200 provided by the floor planks 220, ceiling planks 240, and end pieces 270 may be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, etc. In other configurations, perimeter structures of enclosure members, described below, may be employed in addition to or in place of the outer edge reinforcement of the type described above for the wall member 200.

[0049] Wall Sectionalization Sectionalized wall section of Type 1 structure (151) 2A, each of the two short wall members 200b of the Type 1 structure 151 includes a first wall portion 200b-1 and a second wall portion 200b-2. Each of the wall portions 200b-1 and 200b-2 is a generally rectangular planar structure. A vertical inner edge 191-1 of each of the wall portions 200b-1 is proximate to a vertical inner edge 191-2 of each of the wall portions 200b-2. An inner edge reinforcement may be provided on any one or more of the vertical edges 191-1 and 191-2, examples of which include laminated strand timber boards, wood boards, C-channel extruded aluminum or steel.

[0050] Referring again to FIG. 2A, the two first wall portions 200b-1 are located opposite each other on the floor portion 300a in fixed positions proximate the first lateral edge 108 and the second lateral edge 110 of the completed structure 150. Each first wall portion 200b-1 is joined to the second wall portion 200b-2 by means of hinge structures. These hinge structures allow the second wall portions 200b-2 to pivot about a vertical axis 191 between a folded position and an unfolded position. FIG. 2A shows both the second portion 200b-2 in an unfolded position (referred to as 200b-2u) and in an inwardly folded position (referred to as 200b-2f). When the second portion 200b-2 is in the folded position, the second portion 200b-2 facilitates the formation of a compact shipping module. When the second portion 200b-2 is in the deployed position, the second portion 200b-2 together with the first portion 200b-1 form the short wall member 200b of the Type 1 structure 151 shown in FIG. 2A.

[0051] Sectionalized wall section of Type 2 structure (152) 2B, the type 2 structure 152 has two opposing wall members 200s. One of the opposing wall members 200s includes a first wall portion 200s-1, a second wall portion 200s-2, and a third wall portion 200s-3, and the other of the opposing wall members 200s includes a fourth wall portion 200s-4 and a fifth wall portion 200s-5. Each of the wall portions 200s-1, 200s-2, 200s-3, 200s-4, and 200s-5 has a generally rectangular planar structure. As shown in Figure 2B, vertical inner edge 192-1 of wall portion 200s-1 is proximal to respective vertical inner edge 192-2 of wall portion 200s-2, and vertical inner edge 193-2 of wall portion 200s-2 is proximal to respective vertical inner wall edge 193-3 of wall portion 200s-3. Similarly, as shown in Figure 2B, vertical inner edge 194-4 of wall portion 200s-4 is proximal to respective vertical inner edge 194-5 of wall portion 200s-5. Inner edge reinforcements may be provided on any one or more of vertical edges 192-1, 192-2, 193-3, 194-4, and 194-5, examples of which include laminated strand timber boards, wood boards, C-channel extruded aluminum, or steel.

[0052] 2B, the first wall portion 200s-1 is fixed in position on the floor portion 300a proximal to the first lateral edge 108, and the fourth wall portion 200s-4 is fixed in position on the floor portion 300a opposite the first wall portion 200s-1 and proximal to the second lateral edge 110. The first wall portion 200s-1 is joined to the second wall portion 200s-2 with a hinge structure that allows the wall portion 200s-2 to pivot about a vertical axis 192 between the folded position and the unfolded position. Furthermore, the second wall portion 200s-2 is joined to the third wall portion 200s-3 with a hinge structure that allows the third wall portion 200s-3 to pivot about a vertical axis 193 between the folded position and the unfolded position. On the opposite wall, the fourth wall portion 200s-4 is joined to the fifth wall portion 200s-5 using a hinge structure that allows the fifth wall portion 200s-5 to pivot about a vertical axis 194 between the folded and deployed positions. In particular, the fifth wall portion 200s-5 is longer than the second wall portion 200s-2 or the third wall portion 200s-3.

[0053] FIG. 2B shows both the second wall portion 200s-2 (referred to as 200s-2u) and the third wall portion 200s-3 (referred to as 200s-3u) in an unfolded position, and shows the fifth wall portion 200s-5 (referred to as 200s-5u) in an unfolded position. FIG. 2B also shows both the second wall portion 200s-2 (referred to as 200s-2f) and the third wall portion 200s-3 (referred to as 200s-3f) in an inwardly folded position, and shows the fifth wall portion 200s-5 (referred to as 200s-5f) in an inwardly folded position. When the second wall portion 200s-2, the third wall portion 200s-3, and the fifth wall portion 200s-5 are in their inwardly folded positions, these portions facilitate the formation of a compact shipping module. When the second wall portion 200s-2 and the third wall portion 200s-3 are in the deployed position, these portions, together with the first portion 200s-1, form the wall member 200s proximal to the first lateral edge 108. When the fifth wall portion 200s-5 is in the deployed position, together with the fourth portion 200s-4, form the wall member 200s proximal to the second lateral edge 110.

[0054] The hinge structures described above (fixing each first wall portion 200b-1 to its second wall portion 200b-2, the first wall portion 200s-1 to the second wall portion 200s-2, the second wall portion 200s-2 to the third wall portion 200s-3, and the fourth wall portion 200s-4 to the fifth wall portion 200s-5) may be surface mounted or inset and may be temporary or permanent. An inner edge reinforcement may be provided to provide an area for fixing the hinge structures, as described above. Suitable hinge structures may be manufactured from, for example, metal, plastic, leather, ferrous or non-ferrous materials. Perimeter enclosure member structures, described below, that include hinge structures, such as tongue-and-groove hinged structures 242 shown in Figure 15, are also suitable for fastening the wall sections together. Such perimeter enclosure member structures may be employed in addition to or instead of the inner edge stiffeners described above.

[0055] Non-compartmental wall members of type 1 structures (151) Compared to the two short wall members 200b of the Type 1 structure 151, each of which is segmented into two parts, the two long wall members 200a shown in FIG. 2A do not include multiple wall portions, but rather are each a one-piece structure. However, one of these long wall members 200a is located on the floor portion 300b proximal to the first longitudinal edge 106 and may be referred to as (long) wall member 200a-P in this disclosure, and is pivotally fixed to the floor portion 300b, allowing the wall member 200a-P to pivot about the horizontal axis 105 shown in FIG. 3A from the folded position to the deployed position. Pivotally fixing the long wall members 200a-P also facilitates the formation of a compact shipping module 100. The remaining long wall member 200a, sometimes referred to in this disclosure as 200a-R, is proximal to the second longitudinal edge 116 and is rigidly fixed onto the floor portion 300a abutting the vertical edges of the two first wall portions 200b-1 proximal to the second longitudinal edge 116, as shown in FIG. 2A.

[0056] Non-sectioned wall members of type 2 structures (152) Compared to the two wall members 200s of the type 2 structure 152, each of which is segmented into two parts, the remaining two wall members 200s shown in FIG. 2B do not include multiple wall portions, but rather are each a one-piece structure. However, one of these wall members 200s, which may be referred to in this disclosure as 200s-P and which is located on the floor portion 300b proximal to the first longitudinal edge 106, is pivotally fixed to the floor portion 300b, allowing the wall member 200s-P to pivot about the horizontal axis 105 shown in FIG. 3B from the folded position to the deployed position. Pivotally fixing the wall members 200s-P also facilitates the formation of a compact shipping module 100. The remaining wall member 200s, sometimes referred to in this disclosure as 200s-R, is proximal to the second longitudinal edge 116 and is rigidly fixed onto the floor portion 300 abutting the vertical edges of the first wall portion 200s-1 and the fourth wall portion 200s-4 proximal to the second longitudinal edge 116, as shown in FIG. 2B.

[0057] The hinge structures described above for fixing the wall portions 200a-P to the floor portion 300b and the wall portions 200s-P to the floor portion 300b can be surface mounted or recessed and can be temporary or permanent. An edge reinforcement can be provided to provide an area for fixing the hinge structures as described above. Suitable hinge structures can be manufactured from, for example, metal, plastic, leather, ferrous or non-ferrous materials. In another embodiment, the perimeter structures of the enclosure members described below that include the hinge structures are also suitable for fixing the wall members described above to their respective floor portions 300b (assuming a 90 degree joint between the floor portion 300b and the wall members 200a-P / 200s-P when either of the wall members 200a-P / 200s-P is in the deployed position, modified accordingly). Such perimeter structures of the enclosure members can be employed in addition to or instead of the edge reinforcements described above.

[0058] Wall Chase 4A-4C, the foam panels 214 may be provided with a series of elongated, generally parallel, generally vertically oriented cylindrical passages spaced apart at regular intervals across the distance between the end pieces 270, each spanning the distance between the floor plate 220 and the ceiling plate 240. These vertical passages are referred to as wall chases 219 and can be seen in wall members 200a, 200b of the Type 1 Structure 151 in FIG. 6A and in wall member 200s of the Type 2 Structure 152 in FIG. 7A. The wall chases 219 facilitate the installation of utility plumbing (e.g., for power, lighting control, heating, ventilation, and air conditioning (HVAC), HVAC controls, security systems, etc., including energizing and communicating with smoke or heat sensors) within the wall member 200. Further details regarding these wall chases are set forth in U.S. Non-Provisional Patent Application No. 16 / 786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day as the present application, and having the same inventors as the present application. The contents of U.S. Non-Provisional Patent Application No. 16 / 786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day as the present application, and in particular the details regarding the wall chases, and in particular the details shown in paragraphs 0077-0081 and Figures 5A-5C, 6A, and 7A, are hereby incorporated by reference as if fully set forth herein. Where communication between the wall chase 219 and the area above the ceiling plate 240 and / or floor plate 220 is desired and the wall member 200 includes peripheral structures of enclosure members attached to or in place of either or both of the floor plate 220 and ceiling plate 240 as described below, the peripheral structures of those enclosure members may be provided with suitable openings in suitable locations to allow communication to the wall chase 219.

[0059] Wall Customization Options 1A and 2A show a wall member 200 having multiple openings, specifically a door opening 202 for accommodating a door frame and door assembly, and a window opening 204 for accommodating a window frame and window assembly. The multi-laminate construction of the wall member 200 lends itself to a high degree of customization with respect to type, size and location of doors, windows, etc., while the number of openings 202, 204 can be varied according to design preferences. Further details regarding customization of the wall member 200 are described in U.S. Non-Provisional Patent Application No. 16 / 786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day and having the same inventors as the present application. The contents of U.S. Non-provisional Patent Application No. 16 / 786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day and having the same inventors as the present application, and in particular the details relating to wall customization, such as the details shown in paragraphs 0082 to 0084 and Figures 1A and 2A, are incorporated herein by reference as if fully set forth.

[0060] Ceiling material (400) Typically, the completed structure 150 utilizes one ceiling member 400. Thus, the ceiling member 400 is generally the entire ceiling of the completed structure 150. The ceiling member 400 has a generally rectangular perimeter. Figures 6A-7B, among other drawings, show a ceiling member 400 in accordance with the present invention. The perimeter of the ceiling member 400 is defined by a first longitudinal ceiling edge 406, a first lateral ceiling edge 408, a second longitudinal ceiling edge 416, and a second lateral ceiling edge 410. In particular, the (a) first longitudinal ceiling edge 406, (b) first lateral ceiling edge 408, (c) second longitudinal ceiling edge 416, and (d) second lateral ceiling edge 410 of the ceiling member 400 generally coincide (i.e., overlie) the (w) first longitudinal edge 106, (x) first lateral edge 108, (y) second longitudinal edge 116, and (z) second lateral edge 110, respectively, of the completed structure 150. Figures 6A and 6B show the ceiling member 400 of the Type 1 structure 151, and Figures 7A and 7B show the ceiling member 400 of the Type 2 structure 152. The basic structure and design of the ceiling member 400 is the same for both the Type 1 structure 151 and the Type 2 structure 152, is applicable to the structure 150 in general, and is generally applicable to ceiling members 400 of the structure 150 manufactured in accordance with the present disclosure.

[0061] The length and width of the ceiling member 400 can be varied according to design preferences. In the particular embodiment of the Type 1 structure 151 shown in Figures 1A and 2A, the ceiling member 400 (dimensions along the first longitudinal edge 106 and the second longitudinal edge 116) is approximately 39 feet (11.89 m) in length (dimensions along the first longitudinal ceiling edge 406 and the second longitudinal ceiling edge 416) and approximately 19.5 feet (5.94 m) in width (dimensions along the first lateral ceiling edge 408 and the second lateral ceiling edge 410). In the particular embodiment of the Type 2 structure 152 shown in Figures 1B and 2B, the ceiling member 400 is approximately 19 square feet (5.79 m).

[0062] As will be described below, the ceiling member 400 preferably utilizes one of the multi-layer designs described above with respect to Figures 4A-4D.

[0063] The periphery of the ceiling member 400 is generally provided with an outer edge reinforcement. For the embodiment of the ceiling member 400 shown for the type 1 structure 151 in FIG. 6B and the embodiment of the ceiling member 400 shown for the type 2 structure 152 in FIG. 7A, a first shoulder beam 435 is positioned at the first longitudinal ceiling edge 406 of the ceiling member 400, a second shoulder beam 435 (the edge is seen in front in FIG. 7B) is positioned at the second lateral ceiling edge 408 of the ceiling member 400, a third shoulder beam 435 (the edge is seen in front in FIG. 7B) is positioned at the first lateral ceiling outer edge 410 of the ceiling member 400, and a fourth shoulder beam 435 is positioned at the second longitudinal ceiling edge 416 of the ceiling member 400 (see FIG. 6B). In the case of ceiling member 400, in addition to protecting the outer edges of the foam panel material, the outer edge reinforcement provided by shoulder beams 435 helps resist vertical loads and transfer such loads through the underlying wall members 200 that support the ceiling member 400, to the floor below, and then to the foundation of the completed structure 150. Such outer edge reinforcement can also provide areas for fastening similar areas of abutting enclosure members 155 (both underlying and any overlying members).

[0064] The edge reinforcement provided by shoulder beams 435 of ceiling member 400 may be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, etc. In other configurations, perimeter structures of enclosure members, described below, may be employed in addition to or in place of edge reinforcement as described above for ceiling member 400.

[0065] Ceiling Sectionalization The type 1 structure 151 and the type 2 structure 152 each include a ceiling portion 400a, 400b, and 400c. Each of the ceiling portions 400a, 400b, and 400c is a substantially rectangular planar structure, and as illustrated in Figures 6A and 6B, the ceiling portion 400a is adjacent to the ceiling portion 400b, and the ceiling portion 400b is adjacent to the ceiling portion 400c.

[0066] Ceiling part 400c The ceiling portion 400c illustrates, in a schematic manner, the structure of all the ceiling portions 400a, 400b and 400c. With reference to the segment of the ceiling portion 400c shown in FIG. 6C, the ceiling portion 400c utilizes a laminated multi-layer design according to the first embodiment (shown in FIG. 4A) or the second embodiment (shown in FIG. 4B) of the laminated multi-layer design. In this regard, the ceiling portion 400c includes a first structural layer 210 of the structural building panel 211, referred to as the ceiling bottom surface 404, and a second structural layer 215 of the structural building panel 216, referred to as the ceiling top surface 402. Between the ceiling surfaces 402 and 404, there is a foam panel 214, referred to as the ceiling foam panel 414. The inner edge 412c of the ceiling portion 400c abuts the first inner edge 412b of the ceiling portion 400b, as shown in FIG. 6B and FIG. 7A. For the inner edge stiffener, a stiffener board 437 is positioned adjacent to the inner edge 412c.

[0067] Ceiling section 400a The ceiling portion 400a is shown, for example, in Figures 6B and 7A. The ceiling portion 400a is a mirror image of the design and construction of the ceiling portion 400c. The inner edge 412a of the ceiling portion 400a abuts a second inner edge 412b of the ceiling portion 400b, as shown in Figures 6B and 7A. For the inner edge reinforcement, a reinforcement board 437 is positioned adjacent to the inner edge 412a.

[0068] Ceiling part 400b The ceiling portion 400b shown in Figures 6B and 7A is generally the same in design and construction as the ceiling portions 400a and 400c. A first inner edge 412b of the ceiling portion 400b abuts the inner edge 412c of the ceiling portion 400c, and a second inner edge 412b of the ceiling portion 400b abuts the inner edge 412a of the ceiling portion 400a. For the inner edge reinforcement, a reinforcement board 437 is positioned adjacent to the first inner edge 412b of the ceiling portion 400b, and a reinforcement board 437 is positioned adjacent to the second inner edge 412b of the ceiling portion 400b.

[0069] The ceiling member 400 and its components are generally sized in thickness and other respects to accommodate the particular loads that the ceiling member 400 may be subjected to. For example, the particular embodiment of the ceiling member 400 for the Type 2 structure 152 shown in Figures 7A and 7B may utilize a second multi-layer design embodiment (see Figure 4B) in which the structural building panels 211 of the first structural layer 210 / ceiling bottom surface 404 and the structural building panels 216 of the second structural layer 215 / ceiling top surface 402 are 0.25 inch (0.635 cm) thick MgO boards, and the joining strips are 6 inches (15.24 cm) wide and 0.25 inch (0.635 cm) thick MgO boards. The foam panels 214 / ceiling foam panels 414 may be 7.9 inches (20.07 cm) thick, resulting in a roof member 400 that is approximately 8.4 inches (21.34 cm) thick. Additional structural members, such as joists, may be utilized as appropriate to the particular design of the structure 150 to assist in the transfer of vertical loads to one or more shoulder beams 435.

[0070] Referring to the Type 1 structure 151 shown in Figure 6B, the ceiling portion 400a is fixed in position relative to the first portion 200b-1 of the short wall member 200b and the long wall member 200a-R and is joined along an inner longitudinal edge 412a to an abutting inner longitudinal edge 412b of the ceiling portion 400b using a hinge structure. Such hinge structure is adapted to allow the ceiling portion 400b to pivot through an arc of 180 degrees about a horizontal axis 405a, located proximal to the top of the ceiling member 400, between a folded position in which the ceiling portion 400b lies flat against the ceiling portion 400a, and a fully deployed position shown in Figure 6B.

[0071] Additionally, ceiling portion 400b is joined to ceiling portion 400c at an inner longitudinal edge 412b of ceiling portion 400b that abuts inner longitudinal edge 412c of ceiling portion 400c using a hinge structure adapted to allow ceiling portion 400c to pivot through an arc of 180 degrees about a horizontal axis located proximal to the bottom of ceiling member 400 between a folded position in which ceiling portion 400c lies flat against ceiling portion 400b (when ceiling portion 400b lies flat against ceiling portion 400a) and a fully deployed position shown in FIG.

[0072] 7A, the ceiling portion 400a is fixed in place relative to the first wall portion 200s-1, the fourth wall portion 200s-4 and the wall member 200s-R. The ceiling portions 400a, 400b and 400c of the Type 2 structure 152 are joined using hinge structures in the same manner as described above in relation to the Type 1 structure 151.

[0073] The hinge structure joining the ceiling sections 400a, 400b and 400c can be surface mounted or recessed and can be temporary or permanent. Suitable hinge structures can be made from, for example, metal, plastic, leather, ferrous or non-ferrous materials. The inner edge reinforcement provided by the stiffening board 437 of the ceiling sections 400a, 400b and 400c can provide a structure for mounting the hinge structure in addition to protecting the edges of the foam panel material. The stiffening board 437 can be made from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, and the like.

[0074] A suitable hinge structure and its associated components are shown in Figure 9, which shows an exemplary hinge structure joining the ceiling sections 400b and 400c. In particular, a plurality of double hinges 413 are arranged side-by-side along a horizontal axis 405b. The double hinges are preferably such that they are recessed below the surface while retaining the ability to pivot up to 180 degrees of arc without causing interference crimping between adjacent ceiling sections. These double hinges can be manufactured by positioning two single hinges together in abutting relationship, each along one of their respective leaves, and welding both hinges together to create one double hinge 413.

[0075] As shown in Figure 9, each of the free leaves of the double hinge 413 is secured to a respective stiffening board 437. Each stiffening board 437 is positioned against the exterior of a web of a C-channel track 308 (manufactured from cold-formed steel) which is secured to an abutting edge of each of the roof sections 400b and 400c, as shown in Figure 9. The same hinge structure may be utilized to secure the ceiling sections 400a and 400b together, but may be rotated 180 degrees to be positioned side-by-side along a horizontal axis 405a to allow the ceiling sections 400b and 400c to be folded into a bellows pattern as shown in Figures 3A and 3B.

[0076] A perimeter structure of the enclosure members described below that includes a hinge structure provides yet another alternative to the hinge structure shown in Figure 7B, specifically a second hinged I-beam structure 268 shown in Figures 14A-14F. Such a perimeter structure of the enclosure members may be employed in addition to or instead of the inner edge reinforcement provided by stiffening boards 437 in ceiling sections 400a, 400b and 400c.

[0077] Utility Service Systems and Ceiling Chases To facilitate wiring of utility piping (e.g., for power, lighting control, HVAC, HVAC control, security systems, etc., including energizing and communicating with smoke or heat sensors), the ceiling member 400 may be provided with a utility service system 460, which is one or more recessed passages in a closed loop configuration and located around the entire periphery of the ceiling member 400 proximate the shoulder beams 435 included in the ceiling sections 400a, 400b, and 400c. Figures 6A and 6B show one embodiment of the utility service system 460 (referred to as 461 in these figures), and Figures 7A and 7B show another embodiment of the utility service system 460 (referred to as 462 in these figures). For the same purpose, the ceiling member 400 may also be provided with a ceiling chase 440, which is a plurality of elongated, spaced-apart cylindrical passages in the ceiling sections 400a, 400b, and 400c. The utility service system 460 is adapted to communicate with both the ceiling chase 440 and the wall chase 219. Further details regarding the utility service system 460 and the ceiling chase 440 of the ceiling member 400 are described in U.S. Non-Provisional Patent Application No. 16 / 786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day, and having the same inventor as the present application. The contents of U.S. Non-Provisional Patent Application No. 16 / 786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day, and having the same inventor as the present application, and in particular the details regarding the utility service system 460 and the ceiling chase 440, such as the details found in paragraphs 0102-0120 and Figures 6A-7E, are incorporated herein by reference as if fully set forth herein.

[0078] Floor member (300) Typically, the completed structure 150 utilizes one floor member 300. Thus, the floor member 300 is generally the entire floor of the completed structure 150. The floor member 300 has a generally rectangular perimeter. Figures 6A and 6B and 7A and 7B show the floor member 300 of the present invention. The perimeter of the floor member 300 is defined by a first longitudinal edge 117, a first lateral edge 120, a second longitudinal edge 119, and a second lateral edge 118. In particular, (a) first longitudinal floor edge 117, (b) first lateral floor edge 120, (c) second longitudinal floor edge 119, and (d) second lateral floor edge 118 generally coincide (i.e., underlie) (w) first longitudinal edge 106, (x) first lateral edge 108, (y) second longitudinal edge 116, and (z) second lateral edge 110, respectively, of the finished structure 150. Figures 6A and 6B show floor member 300 for Type 1 structure 151, and Figures 7A and 7B show floor member 300 for Type 2 structure 152. The basic structure of floor member 300 is the same for both Type 1 structure 151 and Type 2 structure 152 and is generally applicable to floor member 300 for structures 150 manufactured according to the present disclosure.

[0079] The length and width of the floor member 300 can be varied according to design preferences. In the particular embodiment of the Type 1 structure 151 shown in Figures 1A and 2A with the wall members 200a, 200b oriented vertically, the length and width of the ceiling member 300 is comparable to the length and width of the ceiling member 400 of the Type 1 structure 151. Similarly, in the particular embodiment of the Type 2 structure 152 shown in Figures 1B and 2B with the wall members 200s oriented vertically, the length and width of the ceiling member 300 is comparable to the length and width of the ceiling member 400 of the Type 2 structure 152.

[0080] As described below, the flooring section 300 preferably utilizes one of the multi-laminate designs described above with respect to Figures 4A-4D.

[0081] The periphery of each floor member 300 is generally provided with an outer edge reinforcement. As outer edge reinforcements for the embodiment of floor member 300 shown in Figures 7A and 7B, a first foundation beam 320 (edges seen in front in Figure 7A) is positioned at the first longitudinal edge 117 of the floor member 300, a second foundation beam 320 (edges seen in front in Figure 7B) is positioned at the second lateral edge 118 of the floor member 300, a third foundation beam 320 (edges seen in front in Figure 7B) is positioned at the first lateral edge 120 of the floor member 300, and a fourth foundation beam 320 is positioned at the second longitudinal edge 119 of the floor member 300 (edges seen in front in Figure 7A). In the case of floor members 300, the edge reinforcement provided by foundation beams 320, in addition to protecting the edges of the foam panel material, helps to resist vertical loads and transfer such loads to any ceiling members 400 below and then to the underlying wall members 200 and / or to the foundation of the completed structure 150.

[0082] The edge reinforcement provided by the foundation beams 420 of the floor member 300 may be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, etc. In other configurations, perimeter structures of enclosure members, described below, may be employed in addition to or in place of edge reinforcement of the type described above for the floor member 300.

[0083] Floor division The floor member 300 in the type 1 structure 151 and the type 2 structure 152 includes a floor portion 300a and a floor portion 300b. Each of the floor portions 300a and 300b is a generally rectangular planar structure, and the floor portion 300a is adjacent to the floor portion 300b, as illustrated in Figures 6A, 6B, and 7A.

[0084] Floor section 300a. The floor section 300a shown in Figures 6A, 6B and 7A generally illustrates the structure of the floor sections 300a and 300b, which as shown generally utilize a laminated multi-layer design according to the first embodiment (shown in Figure 4A) or the second embodiment (shown in Figure 4B) of the laminated multi-layer design. In this regard, the floor section 300a includes a first structural layer 210 of the structural building panel 211, referred to as the floor bottom surface 304, and a second structural layer 215 of the structural building panel 216, referred to as the floor top surface 302. Between the floor surfaces 302 and 304, there is a foam panel 214, referred to as the floor foam panel 314. The inner edge 301a of the floor section 300a abuts the inner edge 301b of the floor section 300b, as shown in Figure 7A. As an inner edge reinforcement, a reinforcement board 307 is positioned adjacent to the inner edge 301a.

[0085] Floor part 300b Floor section 300b is shown in Figures 6A, 6B and 7A. Floor section 300b is generally the same in design and construction as floor section 300a. The inner edge 301b of floor section 300b abuts the inner edge 301a of floor section 300a, as shown in Figure 7A. As an inner edge reinforcement, a reinforcement board 307 is positioned adjacent to inner edge 301b.

[0086] The floor member 300 and its components are generally sized in thickness and other respects to accommodate the particular loads that the floor member 300 may be subjected to. For example, the particular embodiment of the floor member 300 for the Type 2 structure 152 shown in Figures 7A and 7B may utilize a second multi-layer design embodiment (see Figure 4B) in which the first structural layer 210 / floor bottom surface 304 structural building panel 211 is 0.25 inch (0.635 cm) thick MgO board and the second structural layer 215 / floor top surface 302 structural building panel 216 is 0.5 inch (1.27 cm) thick MgO board. Correspondingly, in this particular embodiment, 6 inch (15.24 cm) wide bonding strips of 0.25 inch (0.635 cm) thick MgO boards are used to bond together the structural building panels 211 of the first structural layer 210 / floor bottom surface 304, and 6 inch (15.24 cm) wide bonding strips of 0.5 inch (1.27 cm) thick MgO boards are used to bond together the structural building panels 216 of the second structural layer 215 / floor top surface 302. The foam panels 214 / floor foam panels 314 can be 11.25 inches (28.575 cm) thick, making the floor section 300 approximately 12 inches (30.48 cm) thick.

[0087] The floor section 300b including the floor member 300 can be folded to facilitate the formation of a compact shipping module. The type 1 structure 151 and the type 2 structure 152 each include such a floor section.

[0088] Referring to the Type 1 structure 151 shown in FIG. 6B, the floor portion 300a is fixed in position relative to the first wall portion 200b-1 of the short wall member 200b and the long wall member 200a-R, and is joined to the floor portion 300b using a hinge structure to allow the floor portion 300b to pivot through an arc of approximately 90 degrees about a horizontal axis 305 located proximal to the floor upper surface 302 between a folded position in which the floor portion 300b is oriented approximately vertically as shown in FIG. 3A, and a fully unfolded position as shown in FIGS. 6A and 6B.

[0089] Similarly, with reference to the Type 2 structure 152 shown in Figure 7A, the floor section 300a is fixed in place relative to the first wall section 200s-1, the fourth wall section 200s-4 and the wall member 200s-R. The floor section 300a is joined to the floor section 300b using a hinge structure in the same manner as described above in relation to the Type 1 structure 151.

[0090] The hinge structure joining the floor sections 300a and 300b can be surface mounted or recessed and can be temporary or permanent. Suitable hinge structures can be manufactured from, for example, metal, plastic, leather, ferrous or non-ferrous materials. An example of a suitable hinge structure and its associated components is shown in FIG. 8. In particular, a plurality of steel hinges 306, for example, approximately 3 inches (7.62 cm) wide by approximately 6 inches (15.24 cm) long, are arranged side by side along a horizontal axis 305 as shown edge-on in FIG. 8. Such hinges are commercially available from McMaster-Carr, Douglasville, Georgia, USA. The hinge structure joining the floor sections 300a and 300b need not be a double hinge. 400 ,, and 401 , is preferred because the hinge structure only needs to pivot approximately 90 degrees of arc and therefore the possibility of crimping the inclusions is less than with the ceiling portion of the ceiling member 400 .

[0091] As shown in Figure 8, each opposing leaf of hinge 306 is secured to an inner edge stiffener, stiffening board 307, provided on each of inner edges 301a and 301b. The stiffening boards 307 in Figure 8 are made from laminated strand timber. Each stiffening board 307 is positioned against the exterior of a web of C-channel tracks 308 (manufactured from cold formed steel), each of which is secured to an abutting edge of each of floor sections 300a and 300b, as shown in Figure 8.

[0092] The perimeter structure of the enclosure members described below that includes a hinge structure provides a further alternative to the hinge structure shown in Figure 8 that joins the floor sections 300a and 300b, specifically the first hinged I-beam structure 258 shown in Figures 13A-13F. Such perimeter structures of the enclosure members may be utilized in addition to or instead of the inner edge reinforcements, as discussed above.

[0093] Baseboard and peripheral board The outer edge of the floor member 300 or a portion thereof, for example the outer edge of the floor section 300b located along the first longitudinal edge 106 of the finished structure 150, may be provided with a baseboard 310. For example, in the Type 1 structure 151 shown in FIG. 3A, the baseboard 310 is shown edge-on, secured to the outer edge of the floor section 300b. Where the baseboard 310 extends around the perimeter of the floor member 300, it is referred to as a perimeter board 312. For example, the Type 2 structure 152 shown in FIGS. 1B and 3B utilizes a perimeter board 312. The vertical dimension (height) of the baseboard 310 (including the perimeter board 312) is preferably greater than the thickness of the floor member 300.

[0094] Floor Chase If necessary, the floor foam panels 314 in the floor section 300 may be provided with a floor chase 319, which is a plurality of elongated spaced apart cylindrical passages in the floor sections 300a and 300b, to facilitate wiring of utility ducts (e.g., for power, lighting control, HVAC, HVAC control, security systems, etc., including energizing and communicating with smoke or heat sensors). Such floor chases 319 are adapted to communicate with the wall chases 219 (see Figures 7A and 7B). Further details regarding the floor chases 319 of the floor section 300 are described in U.S. Non-Provisional Patent Application No. 16 / 786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day and by the same inventor as the present application. The contents of U.S. Non-provisional Patent Application No. 16 / 786,130, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day as this application and having the same inventors, and in particular the details relating to floor chase 319, such as the details shown in paragraphs 0137-0141 and FIG. 7F, are incorporated herein by reference as if fully set forth herein.

[0095] Surrounding structure of enclosure components The perimeter (outer edge) of each enclosure member 155 (wall member 200, floor member 300, ceiling member 400), and any inner edges of the sectioned enclosure members 155, are preferably bonded together by a perimeter enclosure member structure. The perimeter enclosure member structure utilized can vary depending on the particular situation and preference, as described in more detail below.

[0096] Sealing layer A sealing gasket strip or layer, made, for example, from extruded polyvinyl chloride (PVC), may be adhered as desired around the periphery of selected edges of the enclosure member 155, for example, from the wall member 200 through the floor plate 220, end pieces 270, and ceiling plate 240. The gasket strip or layer may be co-extruded with one or more sealing beads or ridges located proximate the center of the strip or layer and oriented along the length of the strip or layer, and having a lower durometer hardness than the strip or layer material. Such a sealing strip or layer functions to seal against the ingress of water to the edge of the enclosure member 155 to which it is secured, and against environmental exposure of that edge.

[0097] Freestanding End Caps(221) The freestanding end cap 221, profiled edge-on in Figure 10, has a general C-channel shape with a length "L", where L is approximately the length of the edge of the planar enclosure member 155 to which the freestanding end cap 221 is secured. The freestanding end cap 221 has two spaced apart elongated flange surfaces 222 joined by an elongated web surface 223 to define a C-channel. The particular profile of the C-channel of the freestanding end cap 221 can be modified as desired to have thickness variations, ridges and / or grooves as appropriate for the intended application.

[0098] When the free-standing end cap 221 is secured to a planar enclosure member 155 comprising two structural layers separated by a filler material, such as a foam panel, the flange surfaces 222 are spaced apart a distance approximately equal to the thickness of the foam panel of the planar enclosure member 155 to which the free-standing end cap 221 is positioned and secured. The free-standing end cap 221 is preferably made from an impact resistant material, such as polyvinyl chloride (PVC) having a high durometer hardness, which is extruded and then cut into sections of length L to form the free-standing end cap 221.

[0099] The free-standing end caps 221 are preferably secured to desired edge locations of one or more enclosure members 155 during manufacturing of the enclosure members 155 at a factory or workshop prior to shipment to a building site. For example, if the planar enclosure member 155 includes two structural layers separated by a foam panel, the free-standing end caps 221, having a length L approximately equal to the length of the appropriate edge of the enclosure member 155, are positioned over the edge of the foam panel such that the web surface 223 abuts or is immediately proximate to the edge of the foam panel. The two structural layers are then positioned over the foam panel to overlap most of the flange surfaces 222, where locating ridges 229 positioned on the outer surface of each flange surface 222 aid in proper overlap and alignment of the structural layers. The freestanding end cap 221 may be secured in place, for example, by applying an adhesive between the overlapping areas of the freestanding end cap 221 and the enclosure member 155, by driving fasteners, such as screws or nail fasteners, into the enclosure member 155 at spaced intervals along the length of one or more of the flange surfaces 222 and the web surface 223, by utilizing a combination of adhesive and fasteners in any of the manners described above, or otherwise secured in place. The freestanding end cap 221 functions to seal against water ingress and environmental exposure to the edges of the enclosure member 155 to which it is secured.

[0100] Reinforced End Caps(224) The edges of the planar enclosure member 155 to which the free-standing end caps 221 are secured may be provided with edge reinforcements, as previously described, fabricated from one or more of laminated strand timber boards, wood, C-channel extruded aluminum or steel, etc., and secured to the outer edges of the enclosure member 155. In other configurations, the edges of the planar enclosure member 155 to which the free-standing end caps 221 are secured may, in appropriate circumstances, terminate in the foam panel 214 without such edge reinforcements.

[0101] As yet another alternative, the sealing function can be combined with the edge reinforcement function by integrating an outer edge reinforcement into the end cap. Referring to FIG. 11, the profile of a reinforced end cap 224 for use in place of the free-standing end cap 221 is shown edge-on. The reinforced end cap 224 has a general C-channel shape with a length "L", where L is approximately the length of the edge of the planar enclosure member 155 to which the free-standing end cap 221 is secured. The reinforced end cap 224 has two spaced apart elongated flange surfaces 225 joined by an elongated web surface 226 to define a C-channel. When the reinforced end cap 224 is secured to a planar enclosure member 155 that comprises two structural layers separated by a filler material, such as a foam panel, the flange surfaces 225 are spaced apart a distance approximately equal to the thickness of the foam panel of the planar enclosure member 155 to which the reinforced end cap 224 is positioned and secured. As with the freestanding end cap 221, the particular profile of the C-channel in the reinforced end cap 224 can be modified as desired to have thickness variations, ridges and / or grooves as appropriate for the intended application.

[0102] The reinforcing end cap 224 includes a reinforcing channel 228, shown edge-on in profile in Figure 11, to provide additional structural rigidity. In particular, the reinforcing channel 228 is a four-sided enclosed space having a generally rectangular cross-sectional configuration and is defined by cavity walls 227 spaced from the web surface 226, which are oriented generally parallel to the web surface 226 and span the distance between the flange surfaces 225.

[0103] If further structural reinforcement is desired, filler reinforcement can be inserted or formed in the reinforcing channel 228. Filler reinforcement can include laminated strand timber boards, wood, aluminum or steel inserts or sleeves in rectangular or other suitable shapes, or expanded foam, concrete or even reinforced concrete or other materials. As a further example of a filler reinforcement, scrap foam and / or scrap MgO boards, which may be a by-product of the manufacturing of the enclosure members 155, can be further cut to the appropriate size to function as inserts or sleeves, or can be shredded and mixed with an epoxy adhesive to form a slurry that is then injected into the reinforcing channel 228. This material, when dried, provides a suitable medium for holding the fasteners used to secure the enclosure members in place relative to one another.

[0104] Generally, the use of the reinforcing channel 228, with or without the additional filler reinforcement described above, can reduce or eliminate the need to position and secure outer edge reinforcements to the edges of the planar enclosure member 155 to which the reinforcing end cap 224 is secured.

[0105] The reinforced end cap 224 is preferably made from an impact resistant material, such as polyvinyl chloride (PVC) having a high durometer hardness, which is extruded and then cut into sections of length L to form the reinforced end cap 224.

[0106] The reinforcing end caps 224 are preferably secured to desired edge locations of one or more enclosure members 155 during manufacturing of the enclosure members 155 at a factory or workshop prior to shipment to a building site. For example, if the planar enclosure member 155 includes two structural layers separated by a foam panel, the reinforcing end caps 224, having a length L approximately equal to the length of the appropriate edge of the enclosure member 155, are positioned over the edge of the foam panel such that the cavity walls 227 abut or are immediately proximate to the edge of the foam panel. The two structural layers are then positioned over the foam panel to overlap most of the flange surfaces 225, where locating ridges 229 positioned on the outer surface of each flange surface 225 aid in proper overlap and alignment of the structural layers. The reinforcing end cap 224 may be secured in place, for example, by applying an adhesive between the overlapping areas of the reinforcing end cap 224 and the enclosure member 155, by fasteners such as screws or nail fasteners spaced along the length of one or more of the flange surfaces 225 and driven into the enclosure member 155, by utilizing a combination of adhesive and fasteners in any of the manners described above, or otherwise. As indicated above, the reinforcing end cap 224 performs both an edge strengthening function and a seal against water ingress and environmental exposure to the edge of the enclosure member 155 to which the reinforcing end cap 224 is secured.

[0107] While described in detail with respect to reinforcing end cap 224, the peripheral structures of the other enclosure members described below (abutment end cap 235, first hinged I-beam structure 258, second hinged I-beam structure 268, tongue and groove hinge structure 242) may also utilize similar reinforcing structures (with or without filled reinforcement), i.e., cavity walls spaced from an elongated web, which are oriented generally parallel to the web and span the distance between associated elongated flanges to define reinforcing channels having a generally closed rectangular cross-sectional configuration.

[0108] Abutment end cap(235) The abutting end cap 235, profiled edge-on in FIG. 12, generally has a C-channel shape with a length "L", where L is the length of the edge of the enclosure member 155 to which the end cap 235 is secured. The abutting end cap 235 has two spaced apart elongated flange surfaces 236 and an elongated web surface 237, which generally define a C-channel. The particular profile of the C-channel of the abutting end cap 235 can be modified as desired to have thickness variations, ridges and / or grooves as appropriate for the intended application. When the abutting end cap 235 is secured to a planar enclosure member 155 comprising two structural layers separated by a foam panel, the flange surfaces 236 are spaced apart a distance approximately equal to the thickness of the foam panel of the planar enclosure member 155 to which the abutting end cap 235 is positioned and secured. The abutting end cap 235 is preferably made from an impact resistant material, such as polyvinyl chloride (PVC) having a high durometer hardness, which is extruded and then cut into sections of length L to form the abutting end cap 235.

[0109] The web surfaces 237 of the abutting end caps 235 are not directly bonded to each of the flange surfaces 236. Rather, an angled fastener ledge 239, shown in FIG. 12, is interposed between each flange surface 236 and the web surface 237. The fastener ledges 239 allow a plurality of spaced apart fasteners, such as nails or screw fasteners, to be driven down through the abutting end caps 235 and into the planar enclosure member 155 which may abut the web surface 237, thereby fastening the abutting end caps 235 to the planar enclosure member 155. The areas of each flange surface 236 proximate the fastener ledges 239 are angled inwardly toward one another at a selected angle, as shown in FIG. 12, to provide access to the fastener ledges 239 while simultaneously shortening the width across the web surface 237, thereby reducing the footprint of the abutting end caps 235, as compared to positioning the fastener ledges 239 outwardly from a completely planar flange surface 236. It is preferred that the areas of each flange surface 236 proximal to the fastening shelf 239 are inclined inwardly toward one another approximately 30 degrees from the plane of the flange surface 236 to which the fastening shelf 239 is proximal, and that each fastening shelf 239 is inclined approximately 60 degrees from the plane of the flange surface to which the fastening shelf 239 is proximal.

[0110] The abutting end cap 235 functions to seal against water ingress to the edge of the enclosure member 155 to which it is secured and against environmental exposure of that edge. In addition, the abutting end cap 235 may also provide a seal against water ingress across the interface with the abutting enclosure member 155. Thus, as shown in FIG. 12, the exterior surface of the web surface 237 may be provided with a number of receiving slots 241 for receiving the sealing beads 234 to form a water-resistant seal between the web abutting end cap 235 and the abutting planar enclosure member. In other embodiments, the sealing beads are co-extruded with the abutting end cap 235 at locations approximating the locations of the receiving slots 241.

[0111] The abutting end caps 235 are preferably secured to the desired edge locations of one or more of the enclosure members 155 during manufacturing of the enclosure member(s) 155 at a factory or workshop prior to shipment to a construction site. For example, if the planar enclosure member 155 includes two structural layers separated by a foam panel, the abutting end caps 235, having a length "L" approximately equal to the length of the appropriate edge of the enclosure member 155, are positioned over the edge of the foam panel such that the web surfaces 237 abut or are immediately proximate to the edge of the foam panel. The two structural layers are then positioned over the foam panel to overlap most of the flange surfaces 236. As shown in FIG. 12, a locating ridge 229 is positioned on the outer surface of each flange surface 236 to aid in proper overlap and alignment of the structural layers. The abutting end cap 235 may be secured to the enclosure member 155, for example, by applying an adhesive between the overlapping areas of the abutting end cap 235 and the enclosure member 155, by driving fasteners such as screws or nail fasteners into the enclosure member 155 at spaced intervals along the length of one or more of the flange surfaces 236 and the web surface 237, by utilizing a combination of adhesive and fasteners in any of the manners described above, or otherwise.

[0112] First hinged I-beam structure 258 A first hinged I-beam structure 258 is shown in Figures 13A-13F. The first hinged I-beam structure 258 provides a means for pivotally mounting two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, such that one can pivot relative to the other through at least a 90 degree arc. The first hinged I-beam structure 258 can also provide a sealing function against water ingress and environmental exposure to the edges of the two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, to which it is secured, and can provide a sealing function to prevent water ingress across the interface between those two edges.

[0113] The first hinged I-beam structure 258 has a first elongated peripheral section 259 of length "L" and a second elongated peripheral section 263 also of length "L", where L is the respective length of the edges of the enclosure member 155 to which the first and second peripheral sections 259, 263 are respectively secured to pivotally join the sections together.

[0114] In particular, Figure 13A shows the profile of a first peripheral section 259 of a first hinged I-beam structure 258, looking edge-on. The first peripheral section 259 is defined by two spaced apart elongated flange surfaces 260 and an elongated web surface 261. One of the flange surfaces 260, flange surface 260a, is joined to the web surface 261 at a first joint, and the other of the flange surfaces 260, flange surface 260b, is joined to the web surface 261 at a second joint. When the first peripheral section 259 is secured to a planar enclosure member 155 comprising two structural layers separated by a foam panel, the width of the web surface 261 (the distance separating the flange surfaces 260a and 260b) is somewhat greater than the thickness of the foam panel of the enclosure member 155 to which the first peripheral section 259 is secured, as will be described in more detail below. The first peripheral section 259 forms a channel that is generally C-shaped in cross section.

[0115] Similar to the first peripheral section 259, the second peripheral section 263 (shown edge-on in profile in FIG. 13A ) of the first hinged I-beam structure 258 is defined by two spaced apart elongated flange surfaces 264 and an elongated web surface 265. One of the flange surfaces 264, flange surface 264a, is joined to the web surface 265 at a third joint, and the other of the flange surfaces 264, flange surface 264b, is joined to the web surface 265 at a fourth joint. When the second peripheral section 263 is secured to a planar enclosure member 155 comprising two structural layers separated by a foam panel, the width of the web surface 265 (the distance separating the flange surfaces 264a and 264b) is somewhat greater than the thickness of the foam panel of the enclosure member 155 to which the second peripheral section 263 is secured, as will be described in further detail below. The second peripheral section 263 forms a channel that has a cross-section that is generally C-shaped. Preferably, the first peripheral section 259 and the second peripheral section 263 each have approximately the same shape and dimensions.

[0116] As shown in Figures 13A-13F, the first peripheral section 259 has a first series of hinge knuckles 267a of length L proximate a first junction between the flange surface 260a and the web surface 261 and a second series of hinge knuckles 267b of length L proximate a second junction between the flange surface 260b and the web surface 261. The geometric shapes of the hinge knuckles 267a and 267b are preferably the same as one another. Similarly, the second peripheral section 263 has a first series of hinge knuckles 266a proximate a third junction between the flange surface 264a and the web surface 265 and a second series of hinge knuckles 266b proximate a fourth junction between the flange surface 264b and the web surface 265. The geometric shapes of the hinge knuckles 266a and 266b are the same as each other and preferably as the hinge knuckles 267a and 267b. It is particularly preferred that the hinge knuckles 267a and 267b of the first peripheral section 259 each have a length D and are spaced apart the same distance D, and it is particularly preferred that the hinge knuckles 266a and 266b of the second peripheral section 263 each have a length D and are spaced apart the same distance D. Figure 13D shows the hinge knuckle arrangement of the second peripheral section 263 having a length L. As shown in this figure, each of the hinge knuckles 267a is in an overlying relationship (vertically aligned) with a respective hinge knuckle 267b, and each of the spaces between adjacent pairs of hinge knuckles 267a is in an overlying relationship (vertically aligned) with a respective space between adjacent pairs of hinge knuckles 267b.

[0117] As shown in Figures 13B and 13E, the hinge knuckles 267a and 266a are joined by a first series of linearly arranged cylindrical steel rods 233 of a total length L that interlock to form a pivotable joint between the first peripheral section 259 and the second peripheral section 263. This pivotable joint allows the first hinged I-beam structure 258 to rotate through at least a 90 degree arc to a fully open (deployed) position as shown in Figures 13C and 13F. The hinge knuckles 266b and 267b are positioned such that the hinge knuckles 266b and 267b interlock when the first hinged I-beam structure 258 is fully open. When so interlocked, a second series of linearly-disposed cylindrical steel rods 233 of total length L can be threaded through hinge knuckles 267b and 266b to lock the first hinged I-beam structural section 258 in a fully open position, as shown in Figures 13E and 13F.

[0118] The first series of linearly arranged cylindrical steel rods 233 are preferably joined end-to-end by threaded connections so that the steel rods 233 function as a single continuous rod to better resist tensile loads. Similarly, the second series of linearly arranged cylindrical steel rods 233 are preferably joined in a similar manner. In one embodiment of the first hinged I-beam structure 258, the first series of linearly arranged cylindrical steel rods 233 and the second series of linearly arranged cylindrical steel rods 233 have a diameter of approximately 0.625 inches (1.5875 cm).

[0119] The design of the first peripheral section 259 and the second peripheral section 263 is such that when the first hinged I-beam structure 258 is fully open, the web surfaces 261 and 265 come into contact, as shown in Figures 13C and 13F. This contacting relationship aids in weather sealing the structure. To further this objective, as shown, for example, in Figure 13A, the outer surface of each of the web surfaces 261 and 265 may be provided with a number of receiving slots 241 for receiving sealing beads (not shown) to form a water-resistant seal between the web surfaces. In other embodiments, the sealing beads may be co-extruded simultaneously with the peripheral section itself in locations approximating the locations of the receiving slots 241. In general, the specific contours of the C-channels of the first peripheral section 259 and the second peripheral section 263 may be modified as desired to have thickness variations, ridges and / or grooves as appropriate for the intended application.

[0120] The first peripheral section 259 and the second peripheral section 263 of the first folded I-beam structure 258 can be manufactured by an extrusion process such as pultrusion, in which a suitable material (in the case of pultrusion, a glass fiber reinforced polymer plastic) is pulled through a suitably shaped die to form a workpiece having generally the web / flange structure of the peripheral sections. As part of the pultrusion process, a cylindrical conduit can be formed in the workpiece proximate to the intended locations for the first / third and second / fourth junctions, and then sections of length D can be machined into the conduit at spaced intervals of length D to form a series of hinge knuckles. In another form, the workpiece can be drawn without such a cylindrical conduit, and then tube sections of length D are secured at spaced intervals of length D to form a series of hinge knuckles. After drawing, the workpiece is divided into divided workpieces of length L to provide the desired peripheral sections of the first folded I-beam structure 258. If the first peripheral section 259 and the second peripheral section 263 have the same geometry (which is preferred), the divided workpieces are interchangeable and can function as one or the other of the first peripheral section 259 and the second peripheral section 263. However, when pairing any two workpieces to form the first folded I-beam structure 258, their interlacing relationship must be considered. Thus, for example, when dividing two workpieces into peripheral sections of length L with hinge knuckles of length D spaced apart by a distance of length D, the first of the two works can be divided at the point where the hinge knuckles begin, and accordingly the second of the two works should be divided at the point where the distance of length D begins.

[0121] The first folded I-beam structure 258 can be secured to two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, that are intended to have a folded relationship in the shipping module 100. In FIG. 13C, the two adjacent enclosure members 155 are designated 155a and 155b, and as shown, each enclosure member 155a, 155b has a first structural layer 210a, 210b, respectively, a foam panel 214a, 214b, respectively, and a second structural layer 215a, 215b, respectively. The first folded I-beam structure 258 has a length "L" (L is approximately equal to the length of the corresponding edge of the two adjacent enclosure members 155a and 155b). As seen in Figure 13C, first peripheral section 259 and second peripheral section 263 are sized to capture foam panels 214a, 214b of respective enclosure members 155a, 155b between their respective flange surfaces 260, 264 such that web surfaces 261 and 265 abut or are immediately proximate to edges of foam panels 214a, 214b, respectively. Adjacent first structural layers 210a and 210b are then positioned to overlap most of the upper flange surfaces 260, 264, respectively, where locating ridges 229 positioned on those flange surfaces as shown in Figure 13C aid in proper alignment and overlap of first structural layers 210a, 210b. Also, if the lower flange surfaces 260, 264 are intended to capture adjacent second structural layers 215a, 215b of enclosures 155a, 155b, as shown in FIG. 13C, then it is not necessary to provide positioning ridges 229 on the lower flange surfaces 260, 264.

[0122] First and second peripheral sections 259, 263 may each be secured to their respective enclosure members 155 by, for example, applying an adhesive between the overlapping areas of first and second peripheral sections 259, 263 and their respective enclosure members 155, by driving fasteners, such as screws or nail fasteners, into one or more of flange surfaces 260, 264 and web surfaces 261 and 265 at spaced intervals along the length thereof, or by utilizing a combination of adhesive and fasteners in any of the manners described above, or otherwise. Once secured to their respective enclosure members 155, the associated members may be rotated to a fully collapsed position to form shipping module 100, and may be rotated to a fully deployed position upon completion of structure 150 in its intended location.

[0123] Second hinged I-beam structure (268) A second hinged I-beam structure 268 is shown in Figures 14A-14F. The second hinged I-beam structure 268 provides a means for pivotally mounting two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, such that one can pivot up to 180 degrees of arc relative to the other without causing a crimp of an inclusion between the adjacent members or portions. The second hinged I-beam structure 268 can also provide a sealing function against water ingress and environmental exposure to the edges of the two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, to which it is secured, and can provide a sealing function to prevent water ingress across the boundary between those two edges.

[0124] The second hinged I-beam structure 268 has a first elongated peripheral section 269 (shown edge-on in profile in FIG. 14A ) of length “L” and a second elongated peripheral section 274 also of length “L”, where L is the respective length of the edges of the enclosure member 155 at which the first and second peripheral sections 269, 274 are each positioned to pivotally join them together.

[0125] 14A , the first peripheral section 269 of the second hinged I-beam structural member 268 is defined by two spaced apart elongated flange surfaces 271 and an elongated web surface 272. One of the flange surfaces 271, flange surface 271a, is joined to the web surface 272 at a first joint, and the other of the flange surfaces 271, flange surface 271b, is joined to the web surface 272 at a second joint. When the first peripheral section 269 is secured to a planar enclosure member 155 comprising two structural layers separated by a foam panel, the flange surfaces 271a, 272b are spaced apart a distance approximately equal to the thickness of the foam panel of the planar enclosure member 155 to which the first peripheral section 269 is positioned and secured, such that the first peripheral section 269 forms a channel that is C-shaped in cross section.

[0126] Similar to the first peripheral section 269, the second peripheral section 274 (shown in edge-on profile in FIG. 14A ) of the second hinged I-beam structure 268 is defined by two spaced apart elongated flange surfaces 277 and an elongated web surface 278. One of the flange surfaces 277, flange surface 277a, is joined to the web surface 278 at a third joint, and the other of the flange surfaces 277, flange surface 277b, is joined to the web surface 278 at a fourth joint. When the second peripheral section 274 is secured to a planar enclosure member 155 that also comprises two structural layers separated by a foam panel, the flange surfaces 277a, 277b are spaced apart a distance approximately equal to the thickness of the foam panel of the planar enclosure member 155 to which the second peripheral section 274 is positioned and secured, such that the second peripheral section 274 forms a channel that is C-shaped in cross section. Preferably, the first peripheral section 269 and the second peripheral section 274 each have approximately the same shape and dimensions.

[0127] 14E and 14F, the first peripheral section 269 has a first series of hinge knuckles 273a of length L formed proximate a first junction between one of the flange surfaces 271 and the web surface 272, and a second series of hinge knuckles 273b of length L formed proximate a second junction between one of the flange surfaces 271 and the web surface 272. The geometric shapes of the hinge knuckles 273a and 273b are preferably the same as one another. Similarly, the second peripheral section 274 has a first series of hinge knuckles 279a proximate a third junction between the flange surface 277 and the web surface 278, and a second series of hinge knuckles 279b proximate a fourth junction between the flange surface 277 and the web surface 278. The geometric shapes of the hinge knuckles 279a and 279b are the same as each other and preferably as the hinge knuckles 273a and 273b. As shown in FIG. 14F, it is particularly preferred that the hinge knuckles 273a and 273b of the first peripheral section 269 each have a length D and are spaced apart the same distance D, and it is particularly preferred that the hinge knuckles 279a and 279b of the second peripheral section 274 each have a length D and are spaced apart the same distance D.

[0128] As shown in Figures 14E and 14F, the series of hinge knuckles 273a and 279a do not interlock, but rather are paired in an abutting relationship. A spacer link 280 having a length less than or approximately equal to the distance D is provided and positioned between each abutting pair of hinge knuckles 273a and 279a. The spacer link 280 has two spaced apart bores 281 of approximately the same diameter as the hinge knuckles 273a and 279a, as shown in Figure 14A. A first series of linearly arranged cylindrical steel rods 233 of total length L is threaded through the hinge knuckles 273a and through one of the bores 281 in each of the spacer links 280 positioned between the hinge knuckles, and a second series of linearly arranged cylindrical steel rods 233 of total length L is threaded through the hinge knuckles 279a and through the other of the bores 281 in each of the spacer links 280 positioned between the hinge knuckles. The first series of linearly arranged cylindrical steel rods are preferably joined end to end by a threaded connection so that the steel rods 233 function as a single continuous rod that better resists tensile loads. Similarly, the second series of linearly arranged cylindrical steel rods 233 are preferably joined in a similar manner. In one embodiment of the second hinged I-beam structural section 268, the first series of linearly arranged cylindrical steel rods 233 and the second series of linearly arranged cylindrical steel rods 233 have a diameter of approximately 0.625 inches (1.5875 cm).

[0129] The knuckle and spacer link arrangement described above forms a pivotable joint connected between the first peripheral section 269 and the second peripheral section 274 that can rotate 180 degrees from a fully folded position (with the outer faces of the web surfaces 272 and 278 forming the same plane (or flush face)) as shown in Figure 14D to a fully open (deployed) position as shown in Figure 14C. The position of the hinge knuckles 273b and 279b is such that the hinge knuckle 273b interlocks with the hinge knuckle 279b when the second hinged I-beam structure 268 is fully open, as shown in Figures 14C and 14E. When so interlocked, a third series of linearly arranged cylindrical steel rods 233 (see FIG. 14F) of total length L can be threaded through the hinge knuckles 273a and 279a to lock the second hinged I-beam structure 268 in a fully open position. Like the first series of linearly arranged cylindrical steel rods 233 and the second series of linearly arranged cylindrical steel rods 233, the third series of linearly arranged cylindrical steel rods 233 are preferably joined end-to-end by threaded connections to function as a single continuous rod that better resists tensile loads. In one embodiment of the second hinged I-beam structure 268, the third series of linearly arranged cylindrical steel rods 233 has a diameter of approximately 0.625 inches (1.5875 cm).

[0130] The design of the first peripheral section 269 and the second peripheral section 274 is such that when the second hinged I-beam structure 268 is fully open, the web surfaces 272 and 278 come into contact, as shown in Figures 14C and 14E. This contacting relationship aids in weather sealing the structure. To further this objective, as shown, for example, in Figure 14A, the outer surface of each of the web surfaces 272 and 278 may be provided with a number of receiving slots 241, each of which receives a sealing bead (not shown) to form a water-resistant seal between the web surfaces. In other embodiments, the sealing beads may be co-extruded simultaneously with the peripheral section itself in locations approximating the locations of the receiving slots 241. In general, the specific contours of the C-channels of the first peripheral section 269 and the second peripheral section 274 may be modified as desired to have thickness variations, ridges and / or grooves as appropriate for the intended application.

[0131] The first peripheral section 269 and the second peripheral section 274 of the second folded I-beam structure 268 can be manufactured by an extrusion process such as pultrusion, in which a suitable material (in the case of pultrusion, a glass fiber reinforced polymer plastic) is pulled through a suitably shaped die to form a workpiece having generally the web / flange structure of the peripheral sections. As part of the pultrusion process, cylindrical conduits can be formed in the workpiece proximate the first / third and second / fourth junctions, and then sections of length D can be machined into the conduit at spaced intervals of length D to form a series of hinge knuckles. In another form, the workpiece can be drawn without such cylindrical conduits, and then tube sections of length D are secured, e.g., with an adhesive, at spaced intervals of length D to form a series of hinge knuckles. After drawing, the workpiece is divided into divided workpieces of length L to form the desired peripheral sections of the second folded I-beam structure 268. Where the first peripheral section 269 and the second peripheral section 274 have the same geometry, which is preferred, the divided workpieces are interchangeable and can function as one or the other of the first peripheral section 269 and the second peripheral section 274. However, in each case, referring to the first peripheral section 269 in FIG. 14F for illustrative purposes, the hinge knuckle 273b (of length D) is not vertically aligned with the hinge knuckle 273a (of length D), but rather is longitudinally displaced with respect to the hinge knuckle 273a by an offset distance φ of D / 2, as shown in FIG. 14F. Similarly, the hinge knuckle 279b (of length D) is not vertically aligned with the hinge knuckle 279a (of length D), but rather is longitudinally displaced with respect to the hinge knuckle 279a by the same offset distance φ of D / 2.

[0132] The second folded I-beam structure 268 can be secured to two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, that are intended to have a folded relationship in the shipping module 100. In FIG. 14C, the two adjacent enclosure members 155 are designated 155a and 155b, and as shown, each enclosure member 155a, 155b has a first structural layer 210a, 210b, respectively, a foam panel 214a, 214b, respectively, and a second structural layer 215a, 215b, respectively. The second folded I-beam structure 268 has a length "L" (L is approximately equal to the length of the corresponding edge of the two adjacent enclosure members 155a and 155b). As seen in Figure 14C, first peripheral section 269 and second peripheral section 274 are dimensioned to capture foam panels 214a, 214b of respective enclosure members 155a, 155b between their respective flange surfaces 271, 277 such that web surfaces 272 and 278 abut or are immediately proximate to edges of foam panels 214a, 214b, respectively. Adjacent first structural layers 210a and 210b are then positioned to overlap most of the upper flange surfaces 271, 277, respectively, where positioning detents 281 positioned on those upper flange surfaces as shown in Figure 14C aid in proper alignment and overlap of first structural layers 210a, 210b. Similarly, adjacent second structural layers 215a and 215b are positioned to overlap most of lower flange surfaces 271, 277, respectively, where positioning detents 281 positioned on those lower flange surfaces as shown in FIG. 14C assist in proper alignment and overlap of second structural layers 215a, 215b.

[0133] First and second peripheral sections 269, 274 may each be secured to their respective enclosure members 155 by, for example, applying an adhesive between the overlapping areas of first and second peripheral sections 269, 274 and their respective enclosure members 155, by driving fasteners, such as screws or nail fasteners, into the respective enclosure members 155 at spaced intervals along the length of one or more of flange surfaces 271, 277 and web surfaces 272 and 278, by utilizing a combination of adhesive and fasteners in any of the manners described above, or otherwise. Once secured to their respective enclosure members 155, the associated members may be rotated to a fully collapsed position to form shipping module 100, and may be rotated to a fully deployed position upon completion of structure 150 in its intended location.

[0134] Tongue and groove hinge structure(242) The tongue and groove hinge structure 242 is profiled and shown edge-on in Figure 15. The tongue and groove hinge structure 242 provides a means for pivotally attaching two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, such that one can pivot relative to the other through at least a 90 degree arc. The tongue and groove hinge structure 242 can also provide a seal against water ingress and environmental exposure to the edges of the two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, to which it is secured, and can provide a seal to prevent water ingress across the interface between those two edges.

[0135] The tongue and groove hinge structure 242 has a first elongated peripheral section 243 of length "L" and a second elongated peripheral section 249 of length "L", where L is the length of each of the edges of two adjacent enclosure members 155 at which the first and second peripheral sections 243, 249 are respectively positioned to pivotally join the sections together.

[0136] 15, the first peripheral section 243 of the tongue and groove hinged structure 242 (shown in profile edge-on in FIG. 15) is defined by two spaced apart elongated flange surfaces 244 and an elongated web surface 245. One of the flange surfaces 244, flange surface 244a, is joined to the web surface 245 at a first joint 246, and the other of the flange surfaces 244, flange surface 244b, is joined to the web surface 245 at a second joint 247. When the first peripheral section 243 is secured to a planar enclosure member 155 comprising two structural layers separated by a foam panel, the flange surfaces 244a, 244b are spaced apart a distance approximately equal to the thickness of the foam panel of the planar enclosure member 155 to which the first peripheral section 243 is positioned and secured, such that the first peripheral section 243 forms a channel that is C-shaped in cross section.

[0137] Similar to the first peripheral section 243, the second peripheral section 249 (shown in profile edge-on in FIG. 15 ) of the tongue-and-groove hinged structure 242 is defined by two spaced apart elongated flange surfaces 250 and an elongated web surface 251. One of the flange surfaces 250, flange surface 250a, is joined to the web surface 251 at a third joint 252, and the other of the flange surfaces 250, flange surface 250b, is joined to the web surface 251 at a fourth joint 253. When the second peripheral section 249 is secured to a planar enclosure member 155 that also comprises two structural layers separated by a foam panel, the flange surfaces 250a, 250b are spaced apart a distance approximately equal to the thickness of the foam panel of the planar enclosure member 155 to which the second peripheral section 249 is positioned and secured, such that the second peripheral section 249 forms a channel that is C-shaped in cross section.

[0138] Referring to FIG. 15, the first peripheral section 243 has a first series of hinge knuckles formed along a first joint 246, and the second peripheral section 249 has a second series of hinge knuckles formed along a third joint 252. The two series of hinge knuckles are joined by a series of linearly arranged cylindrical steel rods 233 of a total length L that interlock to form a pivotable joint between the first peripheral section 243 and the second peripheral section 249. The pivotable joint can rotate through at least 90 degrees of arc. The series of linearly arranged cylindrical steel rods 233 are preferably joined end-to-end by threaded connections so that the steel rods 233 function as a single continuous rod to better resist tensile loads. In one embodiment of the tongue-and-groove hinged structure 242, the series of linearly arranged cylindrical steel rods 233 has a diameter of approximately 0.625 inches (1.5875 cm).

[0139] 15, first peripheral section 243 is provided with an elongated tongue and groove seal portion 254 (shown in edge-on profile in FIG. 15) proximal to second junction 247, and second peripheral section 249 is provided with an elongated tongue and groove seal portion 255 (shown in edge-on profile in FIG. 15) proximal to fourth junction 253. Tongue and groove seal portions 254 and 255 are each aligned approximately tangent to a radius centered on first junction 246 such that when first peripheral section 243 and second peripheral section 249 are rotated relative to one another to bring second junction 247 and fourth junction 253 proximal, tongue and groove seal portions 254 and 255 engage in a mating relationship.

[0140] The particular contours of the C-channels of the first peripheral section 243 and the second peripheral section 249 of the tongue-and-groove hinged structure 242 can be modified as desired to have thickness variations, ridges and / or grooves as appropriate for the intended application. Thus, in FIG. 15, the outer surface of the web surface 245 (the surface outwardly facing the edge of the enclosure member 155 to which the first peripheral section 243 is secured) is provided with a plurality of receiving slots 248 for receiving one or more sealing beads 234 to form a watertight seal, where the sealing beads 234 are pressed against the web surface 251 when the first peripheral section 243 and the second peripheral section 249 are rotated relative to one another to bring the elongated tongue-and-groove seal portions 254 and 255 into mating relationship. In other embodiments, the sealing beads are simultaneously co-extruded with the first peripheral section 243 at locations approximating the locations of the receiving slots 248. In yet another embodiment, one or more sealing beads can be provided proximate one or more of the elongated tongue and groove seal portions 254 and 255 such that a water-resistant seal is formed when the first peripheral section 243 and the second peripheral section 249 rotate relative to one another such that the elongated tongue and groove seal portions 254 and 255 are in a mating relationship.

[0141] The first peripheral section 243 and the second peripheral section 249 of the tongue and groove hinged structure 242 may be manufactured by an extrusion process such as pultrusion, in which a suitable material (in the case of pultrusion, a glass fiber reinforced polymer plastic) is pulled through a suitably shaped die or die's to form a workpiece generally having the web / flange structure of the peripheral sections. The pultrusion may include forming cylindrical conduits that become the hinge knuckles, as described above, or the cylindrical conduits may be added after the pultrusion process, as preferred. Similarly, the elongated tongue and groove seal portions 254 and 255 may be similarly manufactured, subject to the particular seal design and other considerations, as preferred.

[0142] The tongue-and-groove hinged structure 242 can be secured to two adjacent enclosure members 155, or two adjacent portions of enclosure members 155, that are intended to have a folding relationship in the shipping module 100. For example, if the first peripheral section 243 is secured to a planar enclosure member 155 comprising two structural layers separated by a foam panel, the first peripheral section 243, having a length L approximately equal to the length of the corresponding edge of the enclosure member 155, is positioned over the edge of the foam panel such that the web surface 245 abuts or is immediately proximal to the edge of the foam panel. The two structural layers are then positioned over the foam panel to overlap most of the flange surface 244, where the locating ridge 229 positioned on the outer surface of the flange surface 244 proximal to the first joint 246 and the locating ridge 229 positioned proximal to the tongue-and-groove feature 254 aid in proper overlap and alignment of the structural layers.

[0143] Similarly, when the second perimeter section 249 associated with a planar enclosure member 155 comprising two structural layers separated by a foam panel is secured, the second perimeter section 249 having a length L approximately equal to the length of the corresponding edge of the enclosure member 155 is positioned over the edge of the foam panel such that the web surface 251 abuts or is immediately proximal to the edge of the foam panel. The two structural layers are then positioned over the foam panel to overlap a majority of the flange surface 250, where the locating ridge 229 positioned on the outer surface of the flange surface 250 proximal to the third joint 252 and proximal to the tongue and groove feature 255 aid in proper overlap and alignment of the structural layers.

[0144] First and second peripheral sections 243, 249 may each be secured to their respective enclosure members 155 by, for example, applying an adhesive between the overlapping areas of first and second peripheral sections 243, 249 and their respective enclosure members 155, by driving fasteners, such as screws or nail fasteners, into one or more of flange surfaces 244, 250 and web surfaces 245 and 251 at spaced intervals along the length thereof, or by utilizing a combination of adhesive and fasteners in any of the manners described above, or otherwise. Once secured to their respective enclosure members 155, the members may be rotated to a fully collapsed position to form shipping module 100, and may be rotated to a fully deployed position upon completion of structure 150 in its intended location.

[0145] Exemplary arrangements of peripheral structures of enclosure members The exploded view in FIG. 16 of the Type 2 structure 152 shown in FIG. 1B provides an exemplary arrangement of the perimeter structures of the enclosure members described herein. In particular, the tongue and groove structure 242 can be utilized to pivotally join the wall portion 200s-1 to the wall portion 200s-2, the wall portion 200s-2 can be pivotally joined to the wall portion 200s-3, and the wall portion 200s-4 can be pivotally joined to the wall portion 200s-5. Also, as shown in FIG. 16, the first hinged I-beam structure 258 can be utilized to pivotally join the floor portion 300a to the floor portion 300b, and the second hinged I-beam structure 268 can be utilized to pivotally join the ceiling portion 400a to the ceiling portion 400b and the ceiling portion 400b to the ceiling portion 400c.

[0146] As further shown in FIG. 16, the abutting end cap 235 can also be utilized to close off the horizontal top and bottom edges of wall member 200s-R, the horizontal top and bottom edges of wall portions 200s-1 to 200s-5, the top edge of wall member 200s-P, the vertical edges of wall portions 200s-1 and 200s-4 that abut wall member 200s-R, and two vertical edges of wall portions 200s-3 and 200s-5 that abut wall member 200s-P. Furthermore, as shown in FIG. 16, the free-standing end caps 221 (or reinforcing end caps 224) can be used to close the horizontal outer edges of the ceiling portions 400a, 400b and 400c that generally coincide with the first longitudinal edge 406, the first lateral edge 408 and the second lateral edge 410 of the ceiling member 400, which would be exposed without the end caps, and the two vertical edges of the wall members 200s-P that would be exposed without the end caps.

[0147] Connection of enclosure components and assembly for transport For ease of transportation and maximum design flexibility, it is preferred that certain dimensional relationships exist between the enclosure members 155 .

[0148] Figure 2A shows a schematic top view of the Type 1 structure 151 shown in Figure 1A with a geometric orthogonal grid for clarity in illustrating the preferred dimensional relationships between the enclosure members 155. The cardinal length used for sizing is shown as "E" in Figure 2A, and the orthogonal grid superimposed in Figure 2A is 24E in length and 12E in width to show the relative dimensions of the members.

[0149] More specifically, in Figure 2A, the two long wall members 200a are approximately 24E in length and the two short wall members 200b are approximately 12E in length. Each of the ceiling sections 400a, 400b and 400c are 24E in length and 4E in width. The two floor sections 300a and 300b of the Type 1 structure 151 are shown in Figures 2A and 3A. Each of the floor members 300a and 300b are 24E in length, while the floor member 300a is approximately 4E in width and the floor member 300b is approximately 8E in width.

[0150] The shipping module 100 of the type 1 structure 151, shown edge-on in Fig. 3A, generally has a fixed space portion 102 defined by a ceiling member 400a, a floor member 300a, a long wall member 200a-R, and two first wall portions 200b-1 of the short wall member 200b. As shown in Fig. 2A, the remaining two portions of the short wall member 200b, the second wall portion 200b-2, are folded inwardly and positioned against the fixed space portion 102 (when so folded and positioned, identified as wall portions 200b-2f in Fig. 2A). The three ceiling portions 400a, 400b, and 400c of the type 1 structure 151 are shown unfolded in Fig. 1A. FIG. 3A, which shows the shipping module 100 of the Type 1 structure 151, shows the ceiling members 400b and 400c stacked on top of the ceiling member 400a, which partially defines the fixed space portion 102. The long wall members 200a-P shown in FIGS. 2A and 3A are pivotally fixed to the floor portion 300b at the location of the horizontal axis 105 and are positioned vertically against the outside of the second wall portion 200b-2. The floor portion 300b is also positioned vertically proximal to the fixed space portion 102, where the long wall members 200a-P are suspended (i.e., hung) from the floor portion 300b between the floor portion 300b and the second wall portion 200b-2.

[0151] Sizing the enclosure members 155 of the Type 1 structure 151 according to the dimensional relationships disclosed above results in a compact shipping module 100, as can be seen in the drawings. Thus, when sized according to the relationships disclosed herein using an "E" dimension (see FIG. 2A) of approximately 19.5 inches (49.5 cm), and the members are stacked and positioned as shown in FIG. 3A, the shipping module 100 has an overall length of approximately 39 feet (11.89 meters), 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 approximately the same as or smaller than a typical shipping container.

[0152] Similarly, Figure 2B shows a schematic top view of the Type 2 completed structure 152 shown in Figure 1B with a geometric orthogonal grid for clarity in illustrating the preferred dimensional relationships between the enclosure members 155. The cardinal length used for sizing is shown as "E" in Figure 2B, and the orthogonal grid superimposed in Figure 2B is approximately 8E in length and 8E in width.

[0153] More specifically, in Figure 2B, the four wall members 200s are approximately 8E in length, and each of the ceiling sections 400a, 400b and 400c are approximately 8E in length and 2.67E in width. The two floor sections 300a and 300b of the completed structure 152 are shown in Figures 2B and 3B. Each of the floor sections 300a and 300b are approximately 8E in length, while floor section 300a is approximately 3E in width and floor section 300b is approximately 5E in width.

[0154] The shipping module 100 of the Type 2 structure 152, shown edge-on in Figure 3B, also generally has a fixed space portion 102 defined by a ceiling member 400a, a floor member 300a, a wall member 200s-R, a wall portion 200s-1, and a wall portion 200s-4. As shown in Figure 2B, the second wall member 200s-2 is folded inwardly and positioned generally against the fixed space portion 102, while the third wall portion 200s-3 is folded outwardly and positioned generally against the second wall portion 200s-2 (wall portions 200s-2 and 200s-3, when so folded and positioned, are identified in Figure 2B as wall portions 200s-2f and 200s-3f, respectively). This forms a bellows fold having the fixed space portion 102, the second wall portion 200s-2 and the third wall portion 200s-3 as its elements. The fifth wall portion 200s-5 is folded inward and positioned generally against the fixed space portion 102 (identified as wall portion 200s-5f in FIG. 2B when so folded and positioned). The three ceiling portions 400a, 400b and 400c are shown in an unfolded state in FIG. 1B. FIG. 3B, showing the shipping module 100 of the Type 2 structure 152, shows the ceiling members 400b and 400c stacked on top of the ceiling member 400a, which partially defines the fixed space portion 102. 2B and 3B, the wall member 200s-P is pivotally fixed to the floor portion 300b at the location of the axis 105 and is positioned vertically adjacent to the outside of the wall portions 200s-3 and 200s-5. The floor portion 300b is also positioned vertically proximal to the fixed space portion 102, where the wall member 200s-P is suspended from the floor portion 300b between the floor portion 300b and the wall portions 200s-3 and 200s-5.

[0155] Sizing the enclosure members 155 of the Type 2 structure 152 according to the dimensional relationships disclosed above results in a compact shipping module 100, as can be seen in the drawings. Thus, the shipping module 100 shown in FIG. 3B, when sized according to the relationships disclosed herein using an "E" dimension (see FIG. 2B) of approximately 29 inches (73.7 cm), and when its members are stacked and positioned as shown in FIG. 3B, 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 smaller than a typical shipping container.

[0156] The referenced geometric orthogonal grid also provides useful reference points for locating floor chases 319, wall chases 219 and ceiling chases 440. If such chases are located, for example, at a particular "E" spacing that matches the grid spacing used, the chases are easily positioned during construction completion.

[0157] The fixed space portion 102 is preferably in a relatively completed state before all other wall, ceiling and floor portions are positioned together (folded) as described above. That is, the fixed space portion 102 is preferably fitted during manufacture with all mechanical and other functions required by the structure 150, such as kitchen, bathroom, laundry room, HVAC closet, fireplace, wardrobe closet, storage area, hallway, etc. The temporary members 103 (shown in FIG. 3A) provide support during shipping of the Type 1 structure 151 and are removed after delivery (no equivalent temporary members are utilized for shipping the Type 2 structure 152). After the fixed space portion 102 is preferably completed to the desired state, the remaining members are folded and positioned against the fixed space portion 102 as described above. Such folded and positioned members allow the builder to construct the completed structure 150 by, in effect, simply "unfolding" (unfolding) the positioned members of the shipping module 100.

[0158] As illustrated by the long wall member 200a in FIG. 5A, each of the wall members 200, floor member 300 and ceiling member 400, and / or portions thereof, can be wrapped with a protective film 177 during manufacture and prior to the formation of the shipping module 100. Alternatively or additionally, the entire shipping module 100 can be wrapped with a protective film. These protective films therefore constitute a means for protecting the shipping module 100 and the members 200, 300 and 400 during shipping. In addition to providing protection to the module and its members, such protective films have the added benefit of increasing the resistance of the members to bending and torsional stresses that may occur during the transportation of the members. These protective films constitute a further means for providing rigidity to the wall member 200, improving its robustness during transportation and the construction of the structure at the construction site. Such protective films preferably remain in place until after the shipping module 100 has reached the construction site, and are then removed as necessary to facilitate the deployment and completion of the enclosure members.

[0159] Shipping Module The shipping module is shipped to the construction site by a suitable transport means. One such transport means is disclosed in U.S. Patent Application Publication No. 2019 / 0100127, filed September 27, 2018, and International Publication No. WO 2019 / 070485, the contents of which, specifically, paragraphs 0020 to 0035 and the contents shown in Figures 1A to 2D, are incorporated herein by reference as if fully set forth. As another transport means, the shipping module 100 can be shipped to the construction site using a conventional truck trailer or a lowbed trailer (also called a lowboy trailer).

[0160] Deployment and completion of the structure At the building site, the shipping module 100 is positioned at its desired location, for example over a prepared foundation, such as a cast-in-place concrete slab, cast-in-place concrete or cinder block foundation, deck beams, or concrete pillars or columns. This can be accomplished by using a crane to lift the shipping module 100 from its transport vehicle and move it to the desired location, or by positioning the transport vehicle over the desired location, lifting the shipping module 100, then moving the transport vehicle from the desired location, and then lowering the shipping module 100 to a resting position at the desired location. Particularly suitable equipment and techniques for facilitating positioning of the shipping module 100 at the desired location are disclosed in U.S. Nonprovisional Patent Application No. 16 / 786,315, entitled "Equipment and Methods for Erecting a Transportable Foldable Building Structure," which has the same inventor and filing date as the present application. The contents of U.S. non-provisional patent application Ser. No. 16 / 786,315, entitled "Equipment and Methods for Erecting a Transportable Foldable Building Structure," which has the same inventor and filing date as this application, are incorporated herein by reference as if fully set forth herein, specifically including, for example, the equipment and techniques described in paragraphs 126-128 and in connection with Figures 11A and 11B.

[0161] After positioning the shipping module 100 at the construction site, the appropriate portions of the wall sections 200, floor sections 300 and ceiling sections 400 are “unfolded” (i.e., unfolded) in the sequence described above to result in the completed structure 150.

[0162] For Type 1 structure 151, deployment (deployment of enclosure members and member portions) occurs in the following order: (1) floor portion 300b is pivotally rotated about horizontal axis 305 shown in Figure 3A to the deployed position, (2) wall members 200a-P are pivotally rotated about horizontal axis 305 shown in Figure 3A to the deployed position, (3) wall portion 200b-2 of short wall member 200b is pivotally rotated about vertical axis 191 shown in Figure 2A to the deployed position, and (4) ceiling portions 400b and 400c are pivotally rotated about horizontal axes 405a and 405b, respectively, to their deployed positions.

[0163] For Type 2 structure 152, deployment occurs in the following order: (1) floor portion 300b is pivotally rotated about horizontal axis 305 shown in FIG. 3B to the deployed position, (2) wall member 200s-P is pivotally rotated about horizontal axis 105 shown in FIG. 3B (behind perimeter board 312) to the deployed position, (3) wall portions 200s-2, 200s-3 and 200s-5 are pivotally rotated about vertical axes 192, 193 and 194, respectively, to the deployed position, and (4) ceiling portions 400b and 400c are pivotally rotated about horizontal axes 405a and 405b, respectively, to the deployed position. A mobile crane may be used to assist in the unfolding of certain enclosure members 155, specifically ceiling portions 400b and 400c, floor portion 300b, and wall members 200 (200a-P for Type 1 structure 151 and 200s-P for Type 2 structure 152) pivotally secured to floor portion 300b. In another aspect, particularly suitable equipment and techniques for facilitating the unfolding of enclosure members 155 are disclosed in U.S. Nonprovisional Patent Application No. 16 / 786,315, entitled "Equipment and Methods for Erecting a Transportable Foldable Building Structure," which has the same inventor and filing date as the present application. The contents of U.S. non-provisional patent application Ser. No. 16 / 786,315, entitled "Equipment and Methods for Erecting a Transportable Foldable Building Structure," which has the same inventor and filing date as this application, are incorporated herein by reference as if fully set forth herein, specifically including, for example, the equipment and techniques described in paragraphs 132-145 and in Figures 12A-14B.

[0164] In particular, the baseboard 310 in the appropriate location acts as a "blocker" that prevents the unfolding of the wall member or wall section in its intended deployed position. Thus, for example, the baseboard 310 in FIG. 3A showing the Type 1 structure 151 prevents the unfolding of the long walls 200a-P shown in this figure when the long walls 200a-P are fully deployed in their desired vertical position. Similarly, the perimeter board 312 in FIG. 3B showing the Type 2 structure 152 performs a similar function for the walls 200s-P, as well as for the wall sections 200s-2, 200s-3 and 200s-5. Furthermore, the baseboard 310 provides a structure for fixing the unfolded wall member in its deployed position. Thus, for example, the baseboard 310 is provided with a number of spaced apart openings 311 in FIG. 6A into which fasteners can be inserted to fix the long wall 200a in place.

[0165] After deployment, the enclosure members 155 are secured together to form the completed structure 150 as shown in Figures 1A and 1B. If any temporary hinge mechanisms are utilized, these can be removed if desired and the enclosure members 155 can be secured together. If any of the selected enclosure member perimeter structures, i.e., abutment end caps 235, first hinged I-beam structure 258, second hinged I-beam structure 268, and tongue and groove hinge structure 242, are utilized, the following completion operations are preferably performed.

[0166] Abutment end cap 235 17, openings 275 are cut in spaced apart locations in any structural layer proximate the fastening ledge 239 of each utilized abutting end cap 235 during manufacturing or prior to shipment of the shipping module 100, or after delivery and deployment. After deployment, fasteners, such as screws or nail fasteners, are driven through the openings 275 and the fastening ledge 239 of the abutting end cap 235 into the underlying enclosure member 155, as shown in FIG. 17, thereby securing the enclosure member 155 utilizing the abutting end cap 235 to the underlying enclosure member 155. The openings are then sealed.

[0167] First hinged I-beam structure 258 After deployment, the hinge knuckles 266b and 267b are interlaced as shown in Figures 13C and 13F. Thus, a second series of linearly arranged cylindrical steel rods 233 can be threaded together and inserted into the hinge knuckles 266b and 267b of the first hinged I-beam structure 258 as shown in Figure 13F to lock the first hinged I-beam structure 258 in a fully open (deployed) position. In such a locked structure, the steel rods are considered to function as tension members (somewhat in the manner of rebar), and the first hinged I-beam structure 258 substantially resists bending along its length. When so locked, the first hinged I-beam structure 258 has particular utility for supporting the completed structure 150 when it is placed on a foundation of a number of concrete pillars or columns.

[0168] The second hinged I-beam structure 268. After deployment, the hinge knuckles 273b and 279b are interlaced as shown in Figures 14C and 14E. Thus, a third series of linearly arranged cylindrical steel rods 233 can be threaded together and inserted into the hinge knuckles 273b and 279b of the second hinged I-beam structure 268 to lock the I-beam structure 268. In such a locking structure, the steel rods can be considered to function as tension members (somewhat in the manner of rebar), and the second hinged I-beam structure 268 substantially resists bending along its length.

[0169] Tongue and groove hinge structure 242 After deployment, the tongue-and-groove features 254 and 255 of all utilized tongue-and-groove structures 242 are engaged in a mating relationship such that fasteners, such as screws or nail fasteners, can be driven into the tongue-and-groove features 254 and 255, for example, to lock the enclosure members 155 to which the tongue-and-groove structures 242 are fastened together in the deployed orientation.

[0170] After deployment and fastening of the enclosure member 155, one or more preselected chases located in the wall member 200, floor member 300 and ceiling member 400 can be wired and connected. Before, during or after deployment and fastening of the enclosure member 155, as desired, openings 202, 204 for one or more doors and windows are cut in the wall member 200 at desired locations and appropriate door and window assemblies are positioned and fastened in the openings 202, 204. In this regard, municipal hook-ups to water and sewer lines are added to complete the structure 150.

[0171] The above detailed description is for the purposes of illustration only and should not be taken as limiting the invention, which is defined in the appended claims.

Claims

1. A reinforcing enclosure member for an architectural structure, comprising: (a) a planar laminate having generally straight edges having a first surface layer, a foamed layer having a first side and an opposite second side, and a second surface layer, the first surface layer being attached to the first side of the foamed layer and the second surface layer being attached to the opposite second side of the foamed layer; (b) a reinforcing end cap, the reinforcing end cap comprising: (1) a first elongated flange surface joined to an elongated web surface at a first junction and a second elongated flange surface joined to the elongated web surface at a second junction, the first elongated flange surface and the second elongated flange surface being spaced apart a predetermined distance, the elongated web surface, the first elongated flange surface and the second elongated flange surface generally forming a C-channel shape; (2) having an elongated cavity wall joined to each of the first and second elongated flange surfaces, the elongated cavity wall being spaced from and generally parallel to the elongated web surface and extending a distance separating the first and second elongated flange surfaces to define a reinforcing channel; and (3) A filler reinforcement material is provided within the reinforcement channel; (c) the reinforcing end cap is secured to the generally straight edge of the planar laminate, the distance separating the first elongated flange surface and the second elongated flange surface being adapted to receive at least the generally straight edge of the foam layer therebetween; The reinforced enclosure member, wherein the first surface layer is a structural layer comprising a plurality of structural panels of magnesium oxide, and the filler reinforcement comprises a dried slurry of magnesium oxide structural panel pieces and an epoxy adhesive.

2. An enclosure member for an architectural structure, comprising: A planar laminate having generally straight edges, the planar laminate having a first surface layer, a foam layer having a first side and an opposite second side, and a second surface layer, the first surface layer being attached to the first side of the foam layer and the second surface layer being attached to the opposite second side of the foam layer. The abutting end cap includes: a first elongated flange surface, an elongated web surface, and a second elongated flange surface, the first elongated flange surface and the second elongated flange surface being spaced apart a predetermined distance, the elongated web surface, the first elongated flange surface, and the second elongated flange surface generally forming a C-channel shape; a first angled fastener ledge joined to the first elongated flange surface and a first edge of the elongated web surface at a first point, and a second angled fastener ledge joined to the second elongated flange surface and a second edge of the elongated web surface at a second point; the abutting end cap is secured to the generally straight edge of the planar laminate, the distance separating the first elongated flange surface and the second elongated flange surface being adapted to receive at least the generally straight edge of the foam layer therebetween; The first elongated flange surface slopes inwardly proximate the first point and the second elongated flange surface slopes inwardly proximate the second point.

3. An enclosure member for an architectural structure, comprising: A planar laminate having generally straight edges, the planar laminate having a first surface layer, a foam layer having a first side and an opposite second side, and a second surface layer, the first surface layer being attached to the first side of the foam layer and the second surface layer being attached to the opposite second side of the foam layer. The abutting end cap includes: a first elongated flange surface, an elongated web surface, and a second elongated flange surface, the first elongated flange surface and the second elongated flange surface being spaced apart a predetermined distance, the elongated web surface, the first elongated flange surface, and the second elongated flange surface generally forming a C-channel shape; a first angled fastener ledge joined to the first elongated flange surface and a first edge of the elongated web surface at a first point, and a second angled fastener ledge joined to the second elongated flange surface and a second edge of the elongated web surface at a second point; the abutting end cap is secured to the generally straight edge of the planar laminate, the distance separating the first elongated flange surface and the second elongated flange surface being adapted to receive at least the generally straight edge of the foam layer therebetween; an elongated cavity wall joined to each of the first and second elongated flange surfaces, the elongated cavity wall being spaced from and generally parallel to the elongated web surface and extending a distance separating the first and second elongated flange surfaces to define a reinforcing channel.

4. A reinforcing enclosure member for an architectural structure, comprising: (a) a planar laminate having generally straight edges having a first surface layer, a foamed layer having a first side and an opposite second side, and a second surface layer, the first surface layer being attached to the first side of the foamed layer and the second surface layer being attached to the opposite second side of the foamed layer; (b) a reinforcing end cap, the reinforcing end cap comprising: (1) a first elongated flange surface joined to an elongated web surface at a first junction and a second elongated flange surface joined to the elongated web surface at a second junction, the first elongated flange surface and the second elongated flange surface being spaced apart a predetermined distance, the elongated web surface, the first elongated flange surface and the second elongated flange surface generally forming a C-channel shape; (2) having an elongated cavity wall joined to each of the first and second elongated flange surfaces, the elongated cavity wall being spaced from and generally parallel to the elongated web surface and extending a distance separating the first and second elongated flange surfaces to define a reinforcing channel; and (3) A filler reinforcement material is provided within the reinforcement channel; (c) the reinforcing end cap is secured to the generally straight edge of the planar laminate, the distance separating the first elongated flange surface and the second elongated flange surface being adapted to receive at least the generally straight edge of the foam layer therebetween; the first surface layer and the second surface layer are each selected from the group consisting of: (a) a structural layer comprising a plurality of structural panels of magnesium oxide; (b) a layer of metal sheet; and (c) a combination of (i) a protective layer comprising a plurality of structural panels of an inorganic oxide and (ii) a layer of metal sheet.

5. An enclosure member for an architectural structure, comprising: A planar laminate having generally straight edges, the planar laminate having a first surface layer, a foam layer having a first side and an opposite second side, and a second surface layer, the first surface layer being attached to the first side of the foam layer and the second surface layer being attached to the opposite second side of the foam layer. The abutting end cap includes: a first elongated flange surface, an elongated web surface, and a second elongated flange surface, the first elongated flange surface and the second elongated flange surface being spaced apart a predetermined distance, the elongated web surface, the first elongated flange surface, and the second elongated flange surface generally forming a C-channel shape; a first angled fastener ledge joined to the first elongated flange surface and a first edge of the elongated web surface at a first point, and a second angled fastener ledge joined to the second elongated flange surface and a second edge of the elongated web surface at a second point; the abutting end cap is secured to the generally straight edge of the planar laminate, the distance separating the first elongated flange surface and the second elongated flange surface being adapted to receive at least the generally straight edge of the foam layer therebetween; the first surface layer and the second surface layer are each selected from the group consisting of: (a) a structural layer comprising a plurality of structural panels of magnesium oxide; (b) a layer of metal sheet; and (c) a combination of (i) a protective layer comprising a plurality of structural panels of an inorganic oxide and (ii) a layer of metal sheet.

6. A collapsible enclosure member for an architectural structure, comprising: (a) a first planar laminate having a first generally straight edge; (b) a second planar laminate having a second generally straight edge; a first planar laminate and a second planar laminate, each of which has a first surface layer, a foam layer having a first surface and an opposite second surface, and a second surface layer, the first surface layer being bonded to the first surface of the foam layer and the second surface layer being bonded to the opposite second surface of the foam layer; (c) a peripheral structure, the peripheral structure comprising: (1) a first peripheral section including a first elongated flange surface joined to a first elongated web surface at a first junction and a second elongated flange surface joined to the first elongated web surface at a second junction, the first elongated flange surface and the second elongated flange surface being spaced apart a first distance, the first elongated web surface, the first elongated flange surface and the second elongated flange surface forming a generally C-channel shape; (2) a second peripheral section including a third elongated flange surface joined to a second elongated web surface at a third junction and a fourth elongated flange surface joined to the second elongated web surface at a fourth junction, the third elongated flange surface and the fourth elongated flange surface being spaced apart a second distance, and the second elongated web surface, the third elongated flange surface and the fourth elongated flange surface generally forming a C-channel shape; (3) the first peripheral section is secured to the first generally straight edge of the first planar laminate, and the first distance separating the first elongated flange surface and the second elongated flange surface is adapted to receive at least the generally straight edge of the foam layer of the first planar laminate therebetween; (4) the second peripheral section is secured to the second generally straight edge of the second planar laminate, and the second distance separating the third elongated flange surface and the fourth elongated flange surface is adapted to receive at least the generally straight edge of the foam layer of the second planar laminate therebetween; (d) the first peripheral section has a first series of hinge knuckles proximal to the first joint and a second series of hinge knuckles proximal to the second joint; (e) the second peripheral section has a third series of hinge knuckles proximal to the third joint and a fourth series of hinge knuckles proximal to the fourth joint; (f) the first series of hinge knuckles interlock with the third series of hinge knuckles; (g) a first cylindrical rod housed in and joining the first and third series of interlocking hinge knuckles to form a pivotable joint between the first and second peripheral sections, the pivotable joint being pivotable from a folded position in which the first elongated web surface is oriented at an angle relative to the second elongated web surface to an unfolded position in which the first elongated web surface is in flush contact with the second elongated web surface; (h) the second series of hinge knuckles are adapted to interlock with the fourth series of hinge knuckles when the pivotable joint is in the deployed position; (i) a second cylindrical rod; (j) the second series of hinge knuckles and the fourth series of hinge knuckles, when interlocked, are adapted to receive the second cylindrical rod and form a rigid I-beam structure between the first perimeter section and the second perimeter section, the rigid I-beam structure including the first perimeter section and the second perimeter section. A collapsible enclosure member.

7. A collapsible enclosure member for an architectural structure, comprising: (a) a first planar laminate having a first generally straight edge; (b) a second planar laminate having a second generally straight edge; Each of the first planar laminate and the second planar laminate has a first surface layer, a foam layer having a first surface and an opposite second surface, and a second surface layer, the first surface layer being bonded to the first surface of the foam layer and the second surface layer being bonded to the opposite second surface of the foam layer; (c) a peripheral structure, the peripheral structure comprising: (1) a first peripheral section including a first elongated web surface having a first elongated edge region and a second elongated edge region, the first peripheral section being secured to the first generally straight edge of the first planar laminate and having a first series of hinge knuckles proximate the first elongated edge region and a second series of hinge knuckles proximate the second elongated edge region; (2) a second peripheral section including a second elongated web surface having a third elongated edge region and a fourth elongated edge region, the second peripheral section being secured to the second generally straight edge of the second planar laminate and having a third series of hinge knuckles proximate the third elongated edge region and a fourth series of hinge knuckles proximate the fourth elongated edge region; (d) the first series of hinge knuckles interlock with the third series of hinge knuckles; (e) a first rod housed in and joining the first and third series of interlocking hinge knuckles to form a pivotable joint between the first and second perimeter sections, the pivotable joint being pivotable from a folded position in which the first elongated web surface is oriented at an angle relative to the second elongated web surface to an unfolded position in which the first elongated web surface is in flush contact with the second elongated web surface; (f) the second series of hinge knuckles are adapted to interlock with the fourth series of hinge knuckles when the pivotable joint is in the deployed position; (g) a second rod; and (h) the second series of hinge knuckles and the fourth series of hinge knuckles are adapted to receive the second rod when interlocked and form a rigid structure between the first perimeter section and the second perimeter section, the rigid structure including the first perimeter section and the second perimeter section. A collapsible enclosure member.

8. A collapsible enclosure member for an architectural structure, comprising: (a) a first planar laminate having a first generally straight edge; (b) a second planar laminate having a second generally straight edge; Each of the first planar laminate and the second planar laminate has a first surface layer, a foam layer having a first surface and an opposite second surface, and a second surface layer, the first surface layer being bonded to the first surface of the foam layer and the second surface layer being bonded to the opposite second surface of the foam layer; (c) a peripheral structure, the peripheral structure comprising: (1) a first peripheral section including a first elongated web surface with first and second elongated edge regions; (2) a second peripheral section including a second elongated web surface with third and fourth elongated edge regions; (3) the first peripheral section is secured to the first generally straight edge of the first planar laminate; (4) the second peripheral section is secured to the second generally straight edge of the second planar laminate; (d) the first peripheral section has a first series of hinge knuckles proximal to the first elongated edge region and a second series of hinge knuckles proximal to the second elongated edge region; (e) the second peripheral section has a third series of hinge knuckles proximal to the third elongated edge region and a fourth series of hinge knuckles proximal to the fourth elongated edge region; (f) the first series of hinge knuckles are paired in abutting relationship with the third series of hinge knuckles to provide a plurality of gaps, each gap being defined by a space between each adjacent abutting pair of the first series of hinge knuckles and the third series of hinge knuckles; (g) a plurality of spacer links, each spacer link having two spaced apart bores, each of the plurality of spacer links positioned within a respective gap of the plurality of gaps; (h) a first cylindrical rod received in a first of the two spaced apart bores of each of the first series of hinge knuckles and the plurality of spacer links to join the first series of hinge knuckles and the plurality of spacer links; (i) receiving a second one of the two spaced apart bores of each of the third series of hinge knuckles and the plurality of spacer links to join the third series of hinge knuckles and the plurality of spacer links; a second cylindrical rod thereby forming a pivotable joint between the first peripheral section and the second peripheral section, the pivotable joint being pivotable from a folded position in which the first elongated web surface is flush with the second elongated web surface to an unfolded position in which the first elongated web surface is in flush contact with the second elongated web surface; (j) the second series of hinge knuckles are configured to interlock with the fourth series of hinge knuckles when the pivotable joint is in the deployed position; (k) a third cylindrical rod; and (l) the second series of hinge knuckles and the fourth series of hinge knuckles, when interlocked, are adapted to receive the third cylindrical rod and form a rigid I-beam structure between the first perimeter section and the second perimeter section, the rigid I-beam structure including the first perimeter section and the second perimeter section.

9. A collapsible enclosure member for an architectural structure, comprising: (a) a first planar laminate having a first generally straight edge; (b) a second planar laminate having a second generally straight edge; Each of the first planar laminate and the second planar laminate has a first surface layer, a foam layer having a first surface and an opposite second surface, and a second surface layer, the first surface layer being bonded to the first surface of the foam layer and the second surface layer being bonded to the opposite second surface of the foam layer; (c) a peripheral structure, the peripheral structure comprising: (1) a first peripheral section including a first elongated flange surface joined to a first elongated web surface at a first junction and a second elongated flange surface joined to the first elongated web surface at a second junction, the first elongated flange surface and the second elongated flange surface being spaced apart a first distance, the first elongated web surface, the first elongated flange surface and the second elongated flange surface forming a generally C-channel shape; (2) a second peripheral section including a third elongated flange surface joined to a second elongated web surface at a third junction and a fourth elongated flange surface joined to the second elongated web surface at a fourth junction, the third elongated flange surface and the fourth elongated flange surface being spaced apart a second distance, and the second elongated web surface, the third elongated flange surface and the fourth elongated flange surface generally forming a C-channel shape; (3) the first peripheral section is secured to the first generally straight edge of the first planar laminate, and the first distance separating the first elongated flange surface and the second elongated flange surface is adapted to receive at least the generally straight edge of the foam layer of the first planar laminate therebetween; (4) the second peripheral section is secured to the second generally straight edge of the second planar laminate, and the second distance separating the third elongated flange surface and the fourth elongated flange surface is adapted to receive at least the generally straight edge of the foam layer of the second planar laminate therebetween; (d) the first peripheral section having a first series of hinge knuckles proximal to the first joint and a first elongated tongue and groove seal proximal to the second joint; (e) the second peripheral section has a third series of hinge knuckles proximal to the third joint and a second elongated rabbet seal proximal to the fourth joint; (f) the first series of hinge knuckles interlock with the third series of hinge knuckles; (g) a first cylindrical rod housed in and joining the first and third series of interlocking hinge knuckles to form a pivotable joint between the first and second perimeter sections; the pivotable joint is pivotable from a folded position in which the first elongated web surface is oriented at an angle relative to the second elongated web surface to an unfolded position in which the first elongated web surface is in flush contact with the second elongated web surface; and (h) the first elongated tongue-and-groove seal portion configured to mate with the second elongated tongue-and-groove seal portion when the pivotable joint is in the deployed position, the collapsible enclosure member.

10. 10. The foldable enclosure member of claim 6 or claim 9, wherein the first peripheral section further comprises a first elongated cavity wall joined to each of the first and second elongated flange surfaces, the first elongated cavity wall being spaced from and generally parallel to the first elongated web surface and extending a first distance separating the first and second elongated flange surfaces to define a first reinforcing channel.

11. 11. The collapsible enclosure member of claim 10, wherein the second peripheral section further comprises a second elongated cavity wall joined to each of the second and fourth elongated flange surfaces, the second elongated cavity wall being spaced from and generally parallel to the second elongated web surface and extending a second distance separating the second and fourth elongated flange surfaces to define a second reinforcing channel.

12. 10. The collapsible enclosure member of claim 6, wherein the first planar laminate and the second planar laminate each have a first surface layer and a second surface layer, respectively, selected from the group consisting of: (a) a structural layer comprising a plurality of structural panels of an inorganic oxide; (b) a layer of a metal sheet; and (c) a combination of (i) a protective layer comprising a plurality of structural panels of magnesium oxide and (ii) a layer of a metal sheet.

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