Collapsible architectural structure with utility channel and laminate enclosure

Abstract

To provide wall components, floor components and ceiling components that can be assembled into structures suitable for human or material occupancy.SOLUTION: An enclosure component having a thickness for a building structure having an interior sheathing layer comprises: a first structural layer bonded to the interior sheathing layer and comprising a first generally rectangular structural panel of magnesium oxide, the first structural panel arranged in a side-by-side relationship with a second generally rectangular structural panel of magnesium oxide to define a first structural panel seam between the first and second structural panels. There is a first binding strip of magnesium oxide positioned over the first structural panel seam and fastened to form a lap joint with the first structural panel and with the second structural panel, so as to bond together the first and second structural panels.SELECTED DRAWING: Figure 1B

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, that are collapsible and easily transportable. [Background technology]

[0003] In the realm of housing complexes, the traditional technique for building a home is called "stick-built" construction, in which builders construct a home at an 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 section of ground, such as a cast-in-place concrete slab, or a cast-in-place concrete or cinder block foundation.

[0004] Many attempts have been made to move away from traditional construction techniques used to create residential and commercial spaces, etc. One alternative to prefabricated construction is more commonly referred to as modular housing. Unlike prefabricated construction, in which the structure is erected on-site, modular homes are constructed in a factory and then shipped to the site, often via tractor-trailer. A drawback of modular housing is that prospective buyers can customize the structure's layout only to a relatively limited extent. 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 changed or adapted to suit the customer's preferences.

[0005] Additionally, modular housing often exceeds the legal size limits typically permitted for road transportation. For example, in the United States, the maximum allowable dimensions for road transportation are typically 102 inches (259.1 cm) wide, 13.5 feet (4.11 m) high, and 65 to 75 feet (19.81 m to 22.86 m) long. Therefore, 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 begin and the route that can be utilized. Oversize road regulations may also require the use of escort vehicles and trailers. All of these requirements and restrictions inevitably increase the cost of modular housing.

[0006] Another form of on-site assembly (stick-built construction) is commonly referred to as a mobile home or trailer home. Mobile homes and trailer homes, like modular homes, are constructed in a factory and then transported to their destination. They can be constructed as two or three separate pieces or sections that are joined at the receiving location, in which case they are called double-wide or triple-wide in the United States. Mobile homes and trailer homes often require less on-site finishing before occupancy than modular homes. On the other hand, such homes are generally mostly one-story or one-story, and their floor plans tend to be essentially dictated by transportation requirements and often cannot be substantially customized by the buyer. Like modular homes, mobile homes and trailer homes often exceed oversized road regulations with the attendant drawbacks mentioned above.

[0007] Yet another approach to prefabricated construction utilizes panels (rather than entire houses or rooms) that are manufactured in a factory and transported to the construction site for assembly and finishing. These panels are typically called structural insulated panels, or SIPs for short. SIP panels are typically foam-core panels with structural boards, such as oriented strand board, facing both sides. The use of SIPs in construction is often considered to offer limited benefits compared to prefabricated construction, since finishing a house, as opposed to framing, is typically the most expensive part of construction. Furthermore, when multiple SIPs are used to form a wall, for example, the intersection between two adjacent SIPs can have a joint or seam that spans the wall's thickness, potentially affecting the rigidity of the structure. Furthermore, when cutting openings for windows and doors or using SIPs to place them on-site, builders must insert a lintel or header at the top of each opening to distribute the vertical load from above each window or door to the load-bearing side. This also increases the cost of using SIPs.

[0008] There are also temporary offices or site trailers, which are similar in size to mobile homes. Temporary offices are simply protected locations, usually steel-clad, that contain storage, offices, and meeting areas. They are not suitable for permanent residence or habitation.

[0009] Significant advances in the construction of residential and commercial spaces are described in U.S. Patent Nos. 5,629,999, 5,729,929, and 5,829,929. 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, which are then transported to an 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]

[0010] [Patent Document 1] U.S. Patent No. 8,474,194 [Patent Document 2] U.S. Patent No. 8,733,029 [Patent Document 3] U.S. Patent Application Publication No. 2019 / 0100908 Summary of the Invention

[0011] The present invention provides a set of wall, floor, and ceiling components that can be manufactured in a factory, delivered to a construction site, and assembled there into a structure suitable for human or material occupancy, such as for use in a residential, office, retail, or warehouse space. The components described herein can be easily shipped from a factory to a construction site. Furthermore, the wall components are configured to support all designed vertical loads as shipped, and despite being factory-manufactured, can be customized on-site with various open-ended door and window styles. Furthermore, the completed structures made in accordance with the inventions disclosed herein can be assembled in numerous configurations. Thus, these inventions have the advantage of giving users both the benefits of individually customized structures and the efficiency and economy of factory manufacturing.

[0012] One form of the invention relates to an enclosure member for a building structure, the enclosure member having a thickness and including an inner covering layer comprising paper, the enclosure member having a first structural layer bonded to the inner covering layer, the first structural layer having a generally rectangular first structural panel of magnesium oxide positioned alongside a generally rectangular second structural panel of magnesium oxide to define a first structural panel joint between the first structural panel and the second structural panel, and the first structural layer having a first bonding strip of magnesium oxide positioned over the first structural panel joint and secured to form a lap joint with the first structural panel and the second structural panel, bonding the first and second structural panels together. The enclosure member includes a first reinforcing layer including a woven fiber mat, the first reinforcing layer being adhered to a first structural layer, the foam layer having a first surface and an opposite second surface, the foam layer including a generally rectangular first foam panel and a generally rectangular second foam panel, the first and second foam panels being arranged in a side-by-side relationship to define a foam panel seam therebetween, the first and second structural panels being positioned relative to the first and second foam panels such that the first structural panel seam is offset a selected distance from the foam panel seam in a direction generally perpendicular to the thickness, and the first reinforcing layer being bonded to the first surface of the foam layer.

[0013] The enclosure member further includes a second structural layer having a generally rectangular third structural panel of magnesium oxide positioned alongside a generally rectangular fourth structural panel of magnesium oxide to define a second structural panel seam between the third and fourth structural panels, and the second structural layer having a second bonding strip of magnesium oxide positioned over the second structural panel seam and secured to form a lap joint with the third and fourth structural panels to bond the third and fourth structural panels together, the third and fourth structural panels being positioned relative to the first and second foam panels such that the second structural panel seam is offset a selected distance from the foam panel seam in a direction generally perpendicular to the thickness, and the second structural layer is adhered to a second opposite surface of the foam layer.

[0014] Another aspect of the present invention is a foldable architectural structure having a fixed spatial portion, the fixed spatial portion having a first floor portion having a thickness defining an interior portion thereof, a first ceiling portion having a thickness defining the interior portion thereof, and a first wall portion having a thickness defining the interior portion thereof, the second ceiling portion being movable between a folded position proximate the fixed spatial portion and an unfolded position, and the third ceiling portion having a thickness defining the interior portion thereof, the third ceiling portion being movable between a folded position proximate the fixed spatial portion and an unfolded position, the second and third ceiling portions being movable from their respective folded positions to their respective unfolded positions and capable of forming a ceiling member of the architectural structure together with the first ceiling portion in their unfolded positions. The first, second, and third ceiling portions define multiple sections of a utility service system within the interior portions of the first, second, and third ceiling portions, respectively, which sections are configured to define a closed-loop utility service system in the interior portions of the ceiling members when the second and third ceiling portions are in their deployed positions, and the utility channel is positioned proximate the periphery of the ceiling member and adapted to contain utility lines.

[0015] These and other aspects of the present invention are illustrated in the drawings attached hereto and in the description of the preferred embodiments and claims that follow. [Brief explanation of the drawings]

[0016] [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] 1 is a schematic top view of a completed structure prepared in accordance with the present invention. [Figure 2B] 1 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] 1 is an exploded cross-sectional view of one embodiment of a laminated multi-layer structure used in the enclosure member of the present invention. FIG. [Figure 4B] 1 is an exploded cross-sectional view of one embodiment of a laminated multi-layer structure used in the enclosure member of the present invention. FIG. [Figure 4C] 1 is an exploded cross-sectional view of one embodiment of a laminated multi-layer structure used in the enclosure member of the present invention. FIG. [Figure 4D] 1 is an exploded cross-sectional view of one embodiment of a laminated multi-layer structure used in the enclosure member of the present invention. FIG. [Figure 5A] FIG. 2 is a cutaway perspective view of a wall member according to the present invention. [Figure 5B] FIG. 2 is a cutaway perspective view of a wall member according to the present invention. [Figure 5C] FIG. 1 is a cutaway perspective view of a wall member illustrating the placement of a wall chase in accordance with the present invention. [Figure 6A] 1 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 a first type of structure according to the present invention; FIG. [Figure 6B] 1 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 a first type of structure according to the present invention; FIG. [Figure 6C] 1 is a partial cutaway perspective view of a completed structure of the present invention showing in greater detail the built-up utility channel of a utility service system of the present invention; FIG. [Figure 6D] 1 is a partial cutaway perspective view of a completed structure of the present invention showing in greater detail the built-up utility channel of a utility service system of the present invention; FIG. [Figure 6E]1 is a plan view of the underside of a ceiling member according to the present invention, including an embodiment of a built-up utility channel of a utility service system according to the present invention. [Figure 7A] 1 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; FIG. [Figure 7B] 1 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; FIG. [Figure 7C] FIG. 1 is a partial cutaway view of a completed structure according to the present invention showing in more detail the construction of a ceiling member using a utility channel in situ in the utility service system of the present invention and illustrating the connection between the wall member and the ceiling member. [Figure 7D] 1 is a cutaway view of a ceiling member of the present invention including a ceiling chase of the present invention and an on-site utility channel configuration of a utility service system. [Figure 7E] FIG. 1 is a cutaway view of a field channel configuration of a utility service system of the present invention showing a channel access plate. [Figure 7F] FIG. 1 is a cutaway view of a floor section illustrating the floor chase of the present invention. [Figure 8] 1 is a schematic side view of one embodiment of a hinge structure joining two floor sections according to the present invention; FIG. [Figure 9] 1 is a schematic side view of one embodiment of a hinge structure joining two roof sections according to the present invention; FIG. [Figure 10] FIG. 1 is an explanatory diagram of a layout of a three-room structure manufactured according to the present invention. [Figure 11] FIG. 1 is a perspective view of a two-story structure manufactured in accordance with the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] 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 as 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 as disclosed herein. While 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. Accordingly, references herein to "structure 150" should be understood to generically refer to Type 1 structure 151 and Type 2 structure 152 without distinction. Similarly, references in this disclosure to components identified with the same reference numeral between different embodiments indicate that such components are the same between such different embodiments.

[0018] 1A and 1B has a rectangular shape made up of three types of generally planar and rectangular enclosure members 155, which consist 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.

[0019] The enclosure members 155 (wall members 200, floor members 300, and ceiling members 400) can be manufactured and dimensioned as described herein and positioned together to form the 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 dimensioned 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 over restricted-access highways and can be transported using appropriate trailer equipment without the need for an oversized load permit. Thus, the foundation members of the completed structure 150 can be manufactured in a factory as described herein and positioned together to form the shipping module 100, which can be transported to a desired site for the structure, where it can be easily assembled and customized.

[0020] Stacking design of enclosure components Laminated multi-layer designs can be used to manufacture the enclosure member 155 of the present invention. Figures 4A-4D show four embodiments of such multi-layer designs for an exemplary enclosure member 155 in exploded cross-sectional views.

[0021] First and second embodiments Internal coating layer (282) 4A and 4B, respectively, the surface of the enclosure member 155 facing toward the interior of the structure 150 is optionally provided with an inner covering layer 282. The inner covering 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 brand name Sheetrock™). The inner covering 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. This compares favorably to traditional construction techniques, whether stickbuilt, SIP, or steel-framed, which require sheets of drywall to first be fastened to the structural elements, and then the joins or seams between adjacent sheets must be smoothed by applying a mortar, such as a spackling compound, and then sanding to create a smooth transition. These expensive and labor-intensive steps of interior finishing can be avoided by using a continuous roll of paper to manufacture the interior covering layer 282 in accordance with the teachings of the present disclosure. Likewise, there is no need to use drywall or other finishes.

[0022] First structural layer (210) A first structural layer 210 is provided in the first embodiment shown in FIG. 4A and the second embodiment shown in FIG. 4B. When used, the inner cover layer 282 is adhered or bonded to this first structural layer 210 using a suitable bonding agent or 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 comprised primarily of a relatively high-strength inorganic composition, such as magnesium oxide (MgO). Suitable structural building panels 211 may be MgO boards approximately 4 feet (1.22 m) wide by approximately 8 feet (2.44 m) long. In certain embodiments of the first embodiment of the multi-layer design of FIG. 4A, those structural building panels 211 using magnesium oxide boards may have a thickness of approximately 0.5 inches (1.27 cm), or alternatively, a thickness of approximately 0.25 inches (0.64 cm) may be employed.

[0023] 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 200a.

[0024] 4A and 4B, respectively, the first structural layer 210 further comprises a plurality of joining strips 212, made from, for example, magnesium oxide board, 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 to the areas of the panels that border the joints, for example, using a suitable adhesive, preferably a polyurethane-based construction adhesive, to form lap joints 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 board 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.

[0025] First Reinforcement Layer (213-1) As shown in first and second embodiments shown in Figures 4A and 4B, respectively, a first reinforcing layer 213-1 is then provided, 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 exemplified by segments 213-1a and 213-1b shown in Figure 4B, positioned between connecting strips 212.

[0026] Foam Panels(214) 4A and 4B, next, in the first and second embodiments, a plurality of generally planar rectangular foam panels 214 are provided that collectively form a first surface and an opposite second surface. 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. Another exemplary arrangement could be to position a plurality of foam panels 214 of sufficient length side by side and vertically to generally cover the entire area of ​​the wall member 200a.

[0027] Preferably, the seams between adjacent foam panels 214 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 can 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 allow. Correspondingly, with foam panels 214 arranged in a checkerboard relationship and structural building panels 211 arranged in a checkerboard relationship, each corner where four foam panels 214 meet can be positioned at or as close to the center of the structural building panel 211 as design, manufacturing, and other considerations allow.

[0028] First reinforcing layer 213-1 is preferably sandwiched between and secured to both first structural layer 210 and the first surface of foam panel 214 using a suitable adhesive, preferably a polyurethane-based construction adhesive. If the fiber fabric of first reinforcing layer 213-1 has a relatively open weave, only a single application of adhesive during manufacture is required to bond layers 210, 213-1, and 214 together into a bonded laminate structure.

[0029] The foam panels 214 provide thermal insulation and also resistance to compressive loads on the enclosure member 155 that may arise through the walls from the roof and upper floors. The first reinforcing layer 213-1 provides strength to the enclosure member 155 and also acts as a burst barrier against moving objects impacting due to weather, which create a risk of penetration into the walls. Adjacent foam panels 214 can be bonded to each other, if desired, by applying a suitable adhesive, preferably a polyurethane-based construction adhesive, between abutting panels.

[0030] Second Reinforcement Layer (213-2) In a first embodiment of a 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 a laminated multi-layer design shown in Figure 4B, a second reinforcing layer 213-2, made from 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 213-2b shown in Figure 4B, positioned between connecting strips 217, as will be described further below.

[0031] 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, positioned on the opposite second surface (distal from the first structural layer 210) of the foam panel 214. In a second embodiment of the laminated multi-layer design shown in FIG. 4B, a second structural layer 215 is also 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 primarily 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 board 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).

[0032] 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 Figure 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 can be positioned side by side vertically to generally cover the entire area of ​​the wall member 200a.

[0033] 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 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, for foam panels 214 arranged in a checkerboard relationship and structural building panels 216 arranged in a checkerboard relationship, each corner where 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 permit. On the other hand, the seams between the structural building panels 211 of the first structural layer 210 can be aligned 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 is acceptable.

[0034] 4A and 4B, respectively, the second structural layer 215 further comprises a plurality of joining strips 217, made of, for example, magnesium oxide board, positioned between the building panels 216 and the foam panels 214. The joining strips 217 are positioned across the linear joints between adjacent panels 216 and then secured to the areas of the panels that border the joints, for example, using a suitable adhesive, preferably a polyurethane-based construction adhesive, 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 joining 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.

[0035] 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 combination, such as may occur in the area proximal to 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.

[0036] In a first embodiment shown in Figure 4A, the second structural layer 215 is secured to the foam panel 214 using, for example, 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 using, for example, 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 may be required during manufacture to bond the layers 214, 213-2, and 215 together into a bonded laminate structure.

[0037] 5B, the outer surfaces 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. Note that the outer surfaces of the panels 216 may be covered with additional protective material unwound from a continuous roll.

[0038] The first embodiment of the laminate multilayer design shown in FIG. 4A is particularly suitable for applications where the combination of first structural layer 210 and first reinforcing layer 213-1 is subject to tensile loads (potentially resulting from loads inducing flexure or bending), but the second structural layer 215 is not subject to tensile loads to a substantial degree. The second embodiment of the laminate multilayer design shown in FIG. 4B is particularly suitable for applications where the combination of both first structural layer 210 and first reinforcing layer 213-1 is subject to tensile loads, and the combination of second structural layer 215 and second reinforcing layer 213-2 is also subject to tensile loads. Reinforcing layers 213-1 and / or 213-2 may be omitted if there is no tensile load in those areas. Additionally, while inner cladding layer 282 is shown adhered to first structural layer 210, inner cladding layer 282 could equally easily be adhered to second structural layer 215, which faces the interior, occupied portion of the structure. The inner coating layer 282 may also be omitted if not desired.

[0039] Third embodiment A third embodiment of a laminated multilayer design is shown in Figure 4C. Compared to the second embodiment shown in Figure 4B, the third embodiment of Figure 4C has a sheet metal layer 205 instead of the second structural layer 215, but is otherwise identical in design to the second embodiment shown in Figure 4B. The sheet metal layer 205, which may be steel or aluminum, is made from a plurality of generally planar rectangular metal sheets 206 positioned adjacent to one another to generally cover the entire area of ​​the intended enclosure member 155 and joined together by riveting, welding, or the like. After joining, the joined metal sheets 206 of the sheet metal layer 205 are secured to the second, opposite side of the foam panel 214 (the side of the foam panel 214 distal from the structural layer 210) by a suitable adhesive application.

[0040] 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 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 allow.

[0041] In this third embodiment, the metal sheets 206 of the sheet metal layers 205 may be fabricated from steel, with protective and / or decorative surface treatments as needed, 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 layers 205 provides increased tensile strength, for example, relative 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. Fourth embodiment

[0042] A fourth embodiment of the laminated multilayer design is shown in Figure 4D. Compared to the third embodiment shown in Figure 4C, the fourth embodiment of Figure 4D includes 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 Figure 4C. The protective layer 293 includes a plurality of generally rectangular protective panels 294 arranged adjacent to one another to generally cover the entire area of ​​the intended enclosure member 155. The protective panels 294 of the protective layer 293 can essentially comprise a fire-resistant inorganic composition, such as magnesium oxide (MgO) or calcium sulfate dihydrate (also known as drywall, and commercially available, for example, under the brand name 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.

[0043] Protective building panel 294 of protective layer 293 is adhered to both foam panel 214 and sheet metal layer 205, with an appropriate adhesive coating applied between protective layer 293 and the second, opposite surface of foam panel 214, and between protective layer 293 and sheet metal layer 205. A suitable thickness for protective building panel 294 of protective layer 293 using magnesium oxide board may be 0.125 inches (3.18 mm). The primary function of protective layer 293 in the fourth embodiment of the laminated multi-layer structure shown in FIG. 4D is to provide fire resistance.

[0044] Outer edge reinforcement for enclosure components The outer edges defining the perimeter of each enclosure member (or enclosure component) 155 may optionally be provided with edge reinforcements. The edge reinforcements may protect the foam panel material that would otherwise be exposed at the outer edges of the enclosure members 155. The edge reinforcements may also serve other functions, as described below. The edge reinforcements may be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, or the like, and are typically secured to the outer edges of the enclosure members 155 using fasteners, such as screws or nail fasteners, and / or adhesives.

[0045] Enclosure component division 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 reinforcement at the outer edge defining the perimeter of the enclosure member is divided between two or more of those portions as needed.

[0046] Inner edge reinforcement for enclosure components The enclosure member 155, segmented into enclosure member portions, will have an inner edge. There will be two adjacent inner edges for each adjacent pair of enclosure member portions. These inner edges may be provided with an inner edge stiffener. Like the outer edge stiffener, such inner edge stiffener can protect the foam panel material that would otherwise be exposed at the inner edge of the enclosure member 155. The inner edge stiffener can also serve other functions, as described below. The inner edge stiffener can be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, etc., and is typically secured to the inner edge of the enclosure member 155 using fasteners, such as screws or nail fasteners, and / or adhesives.

[0047] Further design details of the completed structure 150, wall members 200, floor members 300, and ceiling members 400 are provided in the following sections.

[0048] Wall parts (200) Typically, the 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 vary according to design preference, subject to the dimensional limitations applicable to shipping noted above. In the present disclosure, when the structure 150 is constructed 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, 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, designated 200b, respectively. When structure 150 is made with all sides being approximately equal in length (as is the case with Type 2 structure 152), 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 structure 150 in general.

[0049] 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 the length of 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.

[0050] As noted above, the Type 2 structure 152 shown in FIGS. 1B and 2B has wall members 200, 200s of equal length (respectively designated 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 FIGS. 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.

[0051] 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 elongated wall member 200a shown in Figures 5A and 5B can utilize the second embodiment of the laminated multi-layer design described above with reference to Figure 4B. A specific embodiment of the wall member 200s of the Type 2 structure 152 shown in Figures 1B and 2B referenced above can utilize the second multi-layer design (Figure 4B), in which the structural building panel 211 of the first structural layer 210 and 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 can be 5.5 inches (13.97 cm) thick, resulting in a wall member 200 that is approximately 6 inches (15.24 cm) thick.

[0052] An outer edge reinforcement is typically provided around the periphery of each wall member 200. As exemplified 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. In the case of the wall member 200, the outer edge reinforcement not only protects the outer edges of the foam panel material, but also provides areas for fastening similar areas of the abutting wall member 200, ceiling member 400, and floor member 300.

[0053] The peripheral reinforcement of wall member 200 provided by floor planks 220, ceiling planks 240, and end pieces 270 can be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum, steel, or the like. Alternatively, in addition to or in place of the peripheral reinforcement of the type described above for wall member 200, suitable enclosure component perimeter structures of the type disclosed in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which shares the same inventor and filing date as the present application, are incorporated herein by reference in their entirety, including, for example, the enclosure component perimeter structures described in paragraphs 110-124 and associated with Figures 10-12. In particular, the perimeter structure of these enclosure members can also perform a sealing function to prevent water ingress and environmental exposure.

[0054] 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. The vertical inner edge 191-1 of each of the wall portions 200b-1 is proximal to the vertical inner edge 191-2 of each of the wall portions 200b-2. 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.

[0055] Referring again to FIG. 2A , two first wall portions 200b-1 are located opposite each other on floor portion 300a in fixed positions proximate first lateral edge 108 and second lateral edge 110 of completed structure 150. Each first wall portion 200b-1 is joined to a second wall portion 200b-2 using hinge structures. These hinge structures allow second wall portions 200b-2 to pivot about vertical axis 191 between a folded position and an unfolded position. FIG. 2A shows both second portion 200b-2 (designated 200b-2u) and second portion 200b-2 (designated 200b-2f) in an unfolded, inwardly folded position. When second portion 200b-2 is in the folded position, 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.

[0056] 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 can 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.

[0057] 2B , first wall portion 200s-1 is fixed in place on floor portion 300a proximal to first lateral edge 108, and fourth wall portion 200s-4 is fixed in place on floor portion 300a opposite first wall portion 200s-1 and proximal to second lateral edge 110. First wall portion 200s-1 is joined to second wall portion 200s-2 with a hinge structure that allows wall portion 200s-2 to pivot about vertical axis 192 between the folded position and the unfolded position. Further, second wall portion 200s-2 is joined to third wall portion 200s-3 with a hinge structure that allows third wall portion 200s-3 to pivot about 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.

[0058] 2B shows both second wall portion 200s-2 (referred to as 200s-2u) and third wall portion 200s-3 (referred to as 200s-3u) in the unfolded position, and fifth wall portion 200s-5 (referred to as 200s-5u) in the unfolded position. Also, FIG. 2B shows both second wall portion 200s-2 (referred to as 200s-2f) and third wall portion 200s-3 (referred to as 200s-3f) in the inwardly folded position, and fifth wall portion 200s-5 (referred to as 200s-5f) in the inwardly folded position. When second portion 200s-2, third wall portion 200s-3, and fifth wall portion 200s-5 are in the inwardly folded position, 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, the fifth wall portion 200s-5, together with the fourth portion 200s-4, form the wall member 200s proximal to the second lateral edge 110.

[0059] The hinge structures described above (securing 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) can be surface-mounted or inset and can be temporary or permanent. Inner edge stiffeners can be provided to provide areas for securing the hinge structures, as described above. In another aspect, suitable hinge structures are described in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day and with the same inventor as the present application. The contents of U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which has the same inventor and filing date as the present application, are incorporated herein by reference as if fully set forth, including, for example, the hinge structures described in paragraphs 147-157 and shown in FIG. 15. These hinge structures can be used in addition to or instead of inner edge reinforcements, as described above, and can also perform a sealing function to prevent water intrusion and environmental exposure. Suitable hinge structures can be fabricated, for example, from metal, plastic, leather, ferrous materials, or non-ferrous materials. Perimeter enclosure structure elements, described below, that include hinge structures, such as tongue-and-groove hinged structures 242 shown in Figure 15, are also suitable for securing wall sections together. Such perimeter enclosure structure elements may be employed in addition to or instead of the inner edge stiffeners described above.

[0060] Non-compartmentalized wall members of Type 1 structures (151) In comparison with the two short wall members 200b of Type 1 structure 151, each of which is segmented into two portions, the two long wall members 200a shown in FIG. 2A do not include multiple wall portions but, rather, each is a unitary structure. However, one of these long wall members 200a is located on floor portion 300b proximal to first longitudinal edge 106 and is sometimes referred to in this disclosure as (long) wall member 200a-P, and is pivotally secured to floor portion 300b, allowing wall member 200a-P to pivot about horizontal axis 105 shown in FIG. 3A from a folded position to an unfolded position. Pivotally securing 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 on 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.

[0061] Undivided wall members of Type 2 structures (152) In comparison with the two wall members 200s of the type 2 structure 152, each of which is segmented into two sections, the remaining two wall members 200s shown in FIG. 2B do not include multiple wall sections but rather are each a single unitary structure. However, one of these wall members 200s, sometimes referred to in this disclosure as 200s-P and located on the floor section 300b proximal to the first longitudinal edge 106, is pivotally secured to the floor section 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 securing 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 on 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.

[0062] The hinge structures described above that secure the wall sections 200a-P to the floor section 300b and the wall sections 200s-P to the floor section 300b can be surface-mounted or recessed, and can be temporary or permanent. Edge reinforcements can be provided to provide areas for securing the hinge structures, as described above. Suitable hinge structures can be fabricated from, for example, metal, plastic, leather, ferrous or non-ferrous materials. In another embodiment, a suitable hinge structure is described in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day and having the same inventor as the present application (with appropriate modifications to the hinge structure used assuming a 90-degree joint between floor member 300b and wall member 200a-P / 200s-P when either wall member 200a-P / 200s-P is in the extended position). The contents of U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which has the same inventor and filing date as the present application, are incorporated herein by reference in their entirety, including, for example, the hinge structure described in paragraphs 125-157 and shown in Figures 13A-15. These hinge structures may be utilized in addition to or instead of the outer edge reinforcements, as described above, and may also perform a sealing function to prevent water ingress and environmental exposure.

[0063] Wall Chase 4A-4C , the foam panels 214 may be provided with a series of elongated, generally parallel, and generally vertically oriented cylindrical passages spaced at regular intervals across the entire distance between the end pieces 270, each spanning the distance between the floorboard 220 and the ceiling board 240. These vertical passages, referred to as wall chases 219, can be seen in wall members 200a, 200b of Type 1 Structure 151 in FIG. 6A and in wall member 200s of Type 2 Structure 152 in FIGS. 5C and 7A. The wall chases 219 facilitate the installation of utility plumbing within the wall member 200 (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). In the embodiment shown in FIG. 5C, the wall chases 219 are spaced apart at regular intervals, for example, approximately 29 inches (73.7 cm).

[0064] 5C, a horizontal passageway may be provided above the floor plate 220 and intersecting the wall chase 219. The purpose of this horizontal passageway is to facilitate wiring across the wall member 200, referred to as a connecting wall chase 207. The connecting wall chase 207 may be located, for example, approximately 16 inches (40.64 cm) above the floor plate 220. Although only one horizontal connecting wall chase 207 is shown, one or more additional such wall chases 207 may be provided in the wall member 200, for example, at heights appropriate for wall switches, to facilitate installation and connection of such wall switches. If desired, segments of the connecting wall chase 207 that intersect multiple wall sections are aligned to communicate with each other when such sections are deployed.

[0065] The vertical and horizontal passages in the foam panels 214 that define the wall chases 207 and 219 are preferably formed prior to assembling the foam panels 214 into the laminated, multi-layer structure of the wall member 200. These passages can be formed, for example, by using a hot wire placed above a selected foam panel 214 and oriented parallel to the surface of the foam panel 214 along its length. The hot wire is then moved into the foam panel 214 below the surface of the panel. Once the appropriate depth is reached, the axis of the hot wire is oriented in a circular path so that the length of the wire traces a cylindrical shape within the foam of the foam panel 214, resulting in the formation of a foam plug that is cut from the bulk foam. Removal of the foam plug results in the desired passages that define the wall chases 219 or connecting wall chases 207. Each chase 207, 219 preferably has a diameter sufficient to allow for the installation of utility lines, e.g., approximately 1-2 inches (2.54-5.08 cm) in diameter.

[0066] 5A, 5B, and 5C, which align with the wall chase 219 to allow communication between the upper region of the ceiling plate 240 and the wall chase 219. Similarly, the floor plate 220 includes a plurality of spaced cylindrical through-holes 291, shown in FIG. 5C, which align with the wall chase 219 to allow communication between the lower region of the floor plate 220 and the wall chase 219. If wall member 200 is provided with an enclosure member peripheral structure of the type described in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day and having the same inventor as the present application, bonded thereto or provided in place of one or both of floor plate 220 and ceiling plate 240, such structure can provide holes in the same locations as through holes 209 and 291 to allow communication with wall chase 219.

[0067] The wall chase 219 communicates with a utility service system 460 located within the ceiling member 400, as will be described below.

[0068] 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. A feature of the present invention is that the multi-laminate construction of the wall member 200 lends itself to a high degree of customization with respect to the type, size, and location of doors, windows, etc., while the number of openings 202, 204 can be varied according to design preferences.

[0069] For example, once the structure is assembled in its intended location, a builder can cut door and window openings 202, 204 (as shown in FIG. 1A ) in the wall member 200 according to the purchaser's design choices. Thus, any number, size, and shape of window and door assemblies can be placed virtually anywhere, limited only by retaining enough wall laminate to ensure the structural integrity of the wall component 200 in the face of vertical and shear loads such as might occur during normal use and temporary events (such as storms or seismic activity). The monocoque, laminate, multi-layer construction of the wall component 200 supports loads throughout its entire length, thus allowing significant design freedom without the need for additional load-distributing lintels or headers on-site.

[0070] After the openings are cut to the appropriate size and shape, the window and door assemblies can be inserted and secured to the wall member 200 by adhesive or other suitable means. A wide variety of window and door assemblies are commercially available and suitable for use in the present invention. By way of non-limiting example, a door assembly has all the members or components for mounting and operably activating a door, such as two side jambs, a head frame, and a sill, with the door hinged to one of the side jambs. Similarly, by way of non-limiting example, a window assembly can include all the members or components for mounting and activating a window, such as a sill, side jambs, a head frame, a window frame and glass, a sash pulley, etc.

[0071] 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 figures, 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 with (i.e., overlap) 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 the ceiling member 400 of the structure 150 manufactured in accordance with the present disclosure.

[0072] The length and width of the ceiling member 400 can vary according to design preference. 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).

[0073] 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.

[0074] An outer edge reinforcement is typically provided around the periphery of the ceiling member 400. For the embodiment of the ceiling member 400 shown for the Type 1 structure 151 in Figure 6B and the embodiment of the ceiling member 400 shown for the Type 2 structure 152 in Figure 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 (edge ​​seen in front in Figure 7B) is positioned at the second lateral ceiling edge 408 of the ceiling member 400, a third shoulder beam 435 (edge ​​seen in front in Figure 7B) is positioned at the first outer lateral ceiling 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 Figure 6B). In the case of floor 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 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 (underlying members and any overlying members).

[0075] The peripheral reinforcement provided by the shoulder beams 435 of the ceiling member 400 can be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum, or steel, etc. Alternatively, in addition to or instead of the peripheral reinforcement of the type described above for the ceiling member 400, suitable enclosure member perimeter structures of the type disclosed in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which shares the same inventor and filing date as the present application, can be used. The contents of that U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which shares the same inventor and filing date as the present application, are incorporated herein by reference in their entirety, including, for example, the enclosure member perimeter structures described in paragraphs 110-124 and associated with Figures 10-12. Notably, these enclosure member perimeter structures can further perform a sealing function to prevent water ingress and environmental exposure.

[0076] Ceiling sectioning The type 1 structure 151 and the type 2 structure 152 each include ceiling portions 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.

[0077] Ceiling part 400c Ceiling portion 400c generally illustrates the structure of all ceiling portions 400a, 400b, and 400c. Referring to the segment of ceiling portion 400c shown in FIG. 6C, ceiling portion 400c utilizes a laminated multi-layer design according to either the first embodiment (shown in FIG. 4A) or the second embodiment (shown in FIG. 4B) of the laminated multi-layer design. In this regard, ceiling portion 400c includes a first structural layer 210 of structural building panel 211, referred to as bottom ceiling surface 404, and a second structural layer 215 of structural building panel 216, referred to as top ceiling surface 402. Between ceiling surfaces 402 and 404 is foam panel 214, referred to as ceiling foam panel 414. An inner edge 412c of ceiling portion 400c abuts a first inner edge 412b of ceiling portion 400b, as shown in FIGS. 6B and 7A. For the inner edge stiffener, a stiffener board 437 is positioned adjacent to the inner edge 412c.

[0078] Ceiling section 400a Ceiling portion 400a is shown, for example, in Figures 6B, 6D, and 7A. Ceiling portion 400a is a mirror image of ceiling portion 400c in design and construction. An inner edge 412a of ceiling portion 400a abuts a second inner edge 412b of ceiling portion 400b, as shown in Figures 6B and 7A. For inner edge reinforcement, a reinforcement board 437 is positioned adjacent to inner edge 412a.

[0079] Ceiling part 400b 6B and 7A is generally the same in design and construction as ceiling portions 400a and 400c. A first inner edge 412b of ceiling portion 400b abuts the inner edge 412c of ceiling portion 400c, and a second inner edge 412b of ceiling portion 400b abuts the inner edge 412a of ceiling portion 400a. For inner edge reinforcement, a reinforcement board 437 is positioned adjacent to the first inner edge 412b of ceiling portion 400b, and a reinforcement board 437 is positioned adjacent to the second inner edge 412b of ceiling portion 400b.

[0080] 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 the second multi-layer design embodiment (see Figure 4B) in which the structural building panels 211 of the first structural layer 210 / bottom ceiling 404 and the structural building panels 216 of the second structural layer 215 / top ceiling 402 are 0.25 inch (0.635 cm) thick MgO board, and the tie strips are 0.25 inch (0.635 cm) thick MgO board and 6 inches (15.24 cm) wide. 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 420 (a portion of joists 420 is shown in FIG. 6D ), may be utilized as appropriate for the particular design of structure 150 to assist in the transfer of vertical loads to one or more shoulder beams 435.

[0081] 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.

[0082] 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 collapsed 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.

[0083] 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 similar to those described above in connection with the Type 1 structure 151.

[0084] The hinge structures 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 fabricated from, for example, metal, plastic, leather, ferrous, or non-ferrous materials. The inner edge reinforcement provided by stiffener boards 437 of the ceiling sections 400a, 400b, and 400c can provide a structure for mounting the hinge structures in addition to protecting the edges of the foam panel material. The stiffener boards 437 can be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum, steel, or the like.

[0085] A suitable hinge structure and its associated components are shown in Figure 9, which illustrates an exemplary hinge structure joining ceiling sections 400b and 400c. In particular, multiple double hinges 413 are arranged side-by-side along horizontal axis 405b. The double hinges preferably allow the hinges to be recessed below the surface while retaining the ability to pivot through an arc of 180 degrees 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 the hinges together to create a single double hinge 413.

[0086] As shown in Figure 9, each of the free leaves of double hinge 413 is secured to a respective reinforcing board 437. Each reinforcing board 437 is positioned against the exterior of the web of a C-channel track 308 (fabricated from cold-formed steel), which is secured to the abutting edge of each of roof sections 400b and 400c, as shown in Figure 9. The same hinge structure can be utilized to secure ceiling sections 400a and 400b together, but can be rotated 180 degrees to be positioned side-by-side along horizontal axis 405a to allow ceiling sections 400b and 400c to fold into a bellows pattern as shown in Figures 3A and 3B.

[0087] As yet another alternative to the hinge structure shown in Figure 9, a suitable hinge structure is described in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day and with the same inventor as the present application. The contents of U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which has the same inventor and filing date as the present application, are incorporated herein by reference in their entirety, including, for example, the hinge structure described in paragraphs 125-157 and shown in Figures 13A-15, and more particularly, the hinge structure described in paragraphs 136-146 and shown in Figures 14A-14F. These hinge structures can be used in addition to or instead of the interior edge reinforcement provided by the reinforcement boards 437 in the ceiling sections 400a, 400b and 400c and can also perform a sealing function to prevent water intrusion and environmental exposure.

[0088] Ceiling Chase Each ceiling section 400a, 400b, and 400c may be provided with a ceiling chase 219. The ceiling chase 219 communicates with a utility service system 460 and a wall chase 219, as described below.

[0089] 7D is a plan view of the ceiling 400 of a Type 2 structure 152, sectioned to reveal a particular embodiment of the ceiling chase configuration. While shown for a Type 2 structure 152, the ceiling chase 219 can also be utilized in a Type 1 structure 151, or any other structure 150 manufactured in accordance with the present disclosure.

[0090] As shown in FIG. 7D , a first plurality of elongated cylindrical passages, or ceiling chases 440, are provided, spaced at regular intervals over the entire distance between the first and second lateral ceiling edges 408, 410 and disposed generally parallel to a first direction. The first direction is generally parallel to the first and second lateral ceiling edges 408, 410 and generally parallel to each other. Each such ceiling chase 440 spans the distance between shoulder beams 435 located proximate the first and second longitudinal ceiling edges 406, 416, respectively. A second plurality of ceiling chases 440 are also provided, spaced at regular intervals over the entire distance between the first and second longitudinal ceiling edges 406, 416 and disposed in a second direction that is generally perpendicular to the first direction, generally parallel to the first and second longitudinal ceiling edges 406, 416, and generally parallel to each other. Each such ceiling chase 440 spans the distance between shoulder beams 435 located proximate first and second lateral ceiling edges 408 and 410, respectively. The first and second plurality of spaced-apart ceiling chases thus form a ceiling chase grid. Providing ceiling chase 440 facilitates routing utility lines (such as power, lighting control, HVAC, HVAC control, and security systems including energization and communications for smoke or heat sensors) from wall component 200 to distal locations on ceiling member 400. As shown, ceiling chase segments of ceiling sections 400a, 400b, and 400c are aligned to communicate when ceiling sections 400b and 400c are deployed to form complete ceiling member 400.

[0091] Each ceiling chase 219 preferably has a diameter sufficient to allow for the installation of utility lines, for example, approximately 1-2 inches (2.54-5.08 cm) in diameter. The ceiling chases 219 may be formed in the ceiling foam panel 414 by using a circular hot wire that is appropriately positioned and moved into the foam panel below the surface of the panel in generally the same manner as described above to form the wall chases 207 and 219.

[0092] The ceiling chase 219 communicates with a utility service system 460 located within the ceiling member 400, as will be described below.

[0093] Utility Service Systems(460) As shown in Figures 6A-7E, two embodiments of a utility service system 460 are provided within the ceiling member 400.

[0094] The purpose of the utility service system 460 is to provide a recessed or recessed passageway within the completed structure 150 through which utility piping can be conveniently routed and connected. Generally, the utility service system 460 has one or more passageways disposed around the entire periphery of the ceiling member 400, preferably in a closed loop configuration, i.e., generally adjacent or proximate to the first and second longitudinal ceiling edges 406 and 416 of the ceiling member 400, and generally adjacent or proximate to the first and second lateral ceiling edges 408 and 410. Thus, the structures forming the utility service system 460 are provided in the individual ceiling sections 400a, 400b, and 400c generally proximate to the shoulder beams 435 included in those ceiling sections.

[0095] Utility service system 460 is adapted to accommodate utility piping (e.g., for power, lighting control, heating, ventilation, and air conditioning (HVAC), HVAC control, security systems, etc., including energizing and communicating with smoke or heat sensors). As shown, utility service systems 460 of ceiling sections 400a, 400b, and 400c are aligned to communicate with one another when the ceiling sections are unfolded to form complete ceiling member 400. If used in any of the structural members of ceiling sections 400a, 400b, and 400c, such as joists 420 (as previously mentioned, portions of joists 420 are visible in FIG. 6D ) and / or inner edge reinforcement (such as reinforcement board 437), passage holes 422 (shown in FIG. 6D ) may be provided in the portion spanning utility service system 460 to facilitate free routing of utility lines through the joists and / or reinforcement boards 437 and substantially around the entire perimeter of utility service system 460.

[0096] Two embodiments for a utility service system 460 described herein are a built-up utility channel 461 and an in-situ utility channel 471. Although a built-up utility channel 461 is shown in Type 1 structure 151 and an in-situ utility channel 471 is shown in Type 2 structure 152, either of these utility service systems 460 may be utilized in other types of structures or may be used in other structures manufactured in accordance with the present disclosure.

[0097] Built-in Utility Channel(461) As shown in FIGS. 6A to 6E, the built-up utility channel 461 is a three-sided cavity formed on the underside of the ceiling member 400 and having an outer edge, an inner edge, and an upper portion. As mentioned above, the built-up utility channel 461 preferably forms a closed loop located substantially the entire perimeter of the ceiling member 400 .

[0098] 6C, the outer edge of the built-up utility channel 461 is defined by shoulder beams 435, the inner edge of the channel 461 is defined by channel closure boards 467, and the top of the utility channel 461 is defined by channel top surface 462. Channel closure boards 467 may be fabricated from, for example, one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum or steel, and channel top surface 462 may be fabricated from, for example, magnesium oxide boards approximately 0.5 inches (1.27 cm) thick. The width of the built-up utility channel 461 is preferably sufficient to allow reasonable access for construction and service personnel.

[0099] A first set of multiple openings, referred to as horizontal channel connectors 438, is provided at regular intervals along the inner surface of each shoulder beam 435 of ceiling portions 400a, 400b, and 400c. The horizontal channel connectors 438 may pass completely through the shoulder beam 435, or alternatively, and preferably, terminate within the shoulder beam 435 (as shown in FIG. 6C), creating a cavity in the shoulder beam 435. As shown in FIG. 6C, a second set of multiple openings, referred to as vertical channel connectors 439, is also provided at spaced intervals along the bottom surface of each shoulder beam 435. Each vertical channel connector 439 opens into and communicates with a respective horizontal channel connector 438 to provide a passageway through the shoulder beam 435 from below its bottom surface to out its inner surface.

[0100] The vertical channel connectors 439 are positioned to align with the through holes 209 in the wall members 200 supporting the shoulder beams 435 to provide a passage for passing or routing utility lines from within the utility channel 461 into the wall chase 219 of the wall member 200, and if desired, further into the floor chase 319 of the floor member 300 described below. The horizontal channel connectors 438, vertical channel connectors 439, through holes 209, and wall chase 219 may all be spaced apart at equal intervals, for example, about 29 inches (73.7 cm) apart.

[0101] The built-up utility channel 461 may have multiple serially adjacent removable channel cover plates 464, shown in FIG. 6E, that preferably cover the entire built-up utility channel 461. The channel cover plates 464 conceal the utility lines contained therein and may optionally have lighting accents to enhance the interior space, such as multiple light sources 466, shown in FIG. 6E.

[0102] In-situ Utility Channel(471) 7A-7E, a utility service system 460 may also be formed in-situ in a ceiling foam panel 414. For example, referring to FIG. 7A, a ceiling member 400 including a plurality of ceiling foam panels 414a is shown in cross section. As shown, two in-situ utility channels 471 are provided in the foam panels 414a, each substantially circular in cross section, defining two closed-loop, generally parallel cylindrical passages located approximately the entire periphery of the ceiling member 400 and adjacent to the shoulder beams 435 of the ceiling member 400.

[0103] The utility channels 471 may be formed by using circular hot wires appropriately positioned and moved within the foam panel 414a below the surface of the panel, much as described above for the connection and vertical wall chases 207 and 219, respectively. Each utility channel 471 should have a diameter sufficient to allow for the installation of utility lines, for example, approximately 4 inches (10.16 cm) in diameter.

[0104] 7C , each ceiling chase 440 passes through all or substantially all of the ceiling member 400 between two opposing shoulder beams 435. Each ceiling chase 440 communicates with each of two utility channels 471 at two points (one on each side of the ceiling member 400 proximal to those shoulder beams 435), thereby providing utility routing access between each ceiling chase 440 and the utility channels 471. Proximal to the periphery of the ceiling member 400, each ceiling chase 440 intersects and communicates with a vertically oriented cylindrical passage, a ceiling chase connector 472, which in turn communicates with a respective wall chase 219 through a through-hole 209 in the ceiling plate 240 of the wall member 200. 7C, each ceiling chase connector 472 is formed adjacent to, but outside of, the material of the shoulder beam 435 (within the foam panel 414), and can also be positioned within the material of the shoulder beam 435 as needed or desired, for example, in the manner of the horizontal and vertical channel connectors 438, 439 shown in FIGS. 6C and 6D. The above-described arrangement therefore provides each utility channel 471 with utility routing access to the wall chase 219.

[0105] As shown in Figures 7C-7E, a plurality of channel access openings 473 are provided proximate the intersection of each ceiling chase 440 and utility channel 471 for service access to the utility channel 471. The dimensions of the channel access openings 473 are preferably sufficient to allow reasonable access for construction and service personnel; for example, each channel access opening 473 may have a rectangular configuration approximately 14.5 inches (36.8 cm) wide and 8.0 inches (20.3 cm) long. Each channel access opening 473 may be covered by a removable channel access plate 474, as shown in Figure 7E.

[0106] Use of the Utility Service System As examples of utility lines that may be installed in the utility service system 460, FIG. 6E shows, in schematic form, a two-wire electrical loop 208 installed in a built-up utility channel 461, and FIG. 6A shows four preselected wall chases 219a, 219b, 219c, and 219d within the wall member 200 of the completed structure 150. One or more cutouts 276 are formed to communicate with the wall chases 219a-d, and junction boxes are placed in the cutouts 276 as needed, and the chases are wired and connected to the loop 208. Openings for outlets, switches, lights, etc., can be cut through the interior cover layer 282, the first structural layer 210, the first woven fiber layer 213-1, and the foam panel 214 to form cutouts 276 in the wall chase 219. In a similar manner, cutout openings can be formed in the ceiling member 400 to communicate with the ceiling chase 219. This arrangement provides access to electrical services at many points across wall member 200 and ceiling member 400. Wiring and connection operations are preferably performed after delivery and deployment of structure 150, although the other described operations may be performed before or after delivery, as preferred.

[0107] 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 a floor member 300 in accordance with 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 with (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 members 300 for structures 150 manufactured in accordance with the present disclosure.

[0108] The length and width of the floor member 300 can vary according to design preference. In the particular embodiment of the Type 1 structure 151 shown in Figures 1A and 2A, in which the wall members 200a, 200b are oriented vertically, the length and width of the floor member 400 are 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, in which the wall members 200s are oriented vertically, the length and width of the floor member 400 are comparable to the length and width of the ceiling member 400 of the Type 2 structure 152.

[0109] As will be described below, flooring section 300 preferably utilizes one of the multi-layer designs described above with respect to Figures 4A-4D.

[0110] An outer edge reinforcement is typically provided around the periphery of each floor element 300. As outer edge reinforcement for the embodiment of floor element 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 element 300, a second foundation beam 320 (edges seen in front in Figure 7B) is positioned at the second lateral edge 118 of the floor element 300, a third foundation beam 320 (edges seen in front in Figure 7B) is positioned at the first lateral edge 120 of the floor element 300, and a fourth foundation beam 320 (edges seen in front in Figure 7A) is positioned at the second longitudinal edge 119 of the floor element 300. 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, also helps 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.

[0111] The perimeter reinforcement provided by the foundation beams 420 of the floor member 300 can be fabricated from one or more of laminated strand timber boards, wood boards, C-channel extruded aluminum, or steel, etc. Alternatively, in addition to or instead of the perimeter reinforcement of the type described above for the floor member 300, suitable enclosure member perimeter structures of the type disclosed in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which shares the same inventor and filing date as the present application, can be used. The contents of that application, including, for example, the enclosure member perimeter structures described in paragraphs 110-124 and associated with Figures 10-12, are incorporated herein by reference as if fully set forth. Notably, these enclosure member perimeter structures can also perform a sealing function to prevent water ingress and environmental exposure.

[0112] 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 as illustrated in Figures 6A, 6B, and 7A, the floor portion 300a is adjacent to the floor portion 300b.

[0113] Floor Section 300a. Floor section 300a shown in Figures 6A, 6B, and 7A generally illustrates the construction of floor sections 300a and 300b, which, as shown, generally utilize a laminated multi-layer design according to either the first embodiment (shown in Figure 4A) or the second embodiment (shown in Figure 4B) of the laminated multi-layer design. In this regard, floor section 300a includes a first structural layer 210 of structural building panel 211, referred to as bottom floor surface 304, and a second structural layer 215 of structural building panel 216, referred to as top floor surface 302. Between top floor surface 302 and bottom floor surface 304 is a foam panel 214, referred to as floor foam panel 314. An inner edge 301a of floor section 300a abuts an inner edge 301b of floor section 300b, as shown in Figure 7A. As inner edge reinforcement, a reinforcement board 307 is positioned adjacent to inner edge 301a.

[0114] Floor part 300b Floor section 300b is shown in Figures 6A, 6B, and 7A. Floor section 300b is generally similar in design and construction to floor section 300a. Inner edge 301b of floor section 300b abuts inner edge 301a of floor section 300a, as shown in Figure 7A. As inner edge reinforcement, a reinforcement board 307 is positioned adjacent to inner edge 301b.

[0115] 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 the 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, 0.25 inch (0.635 cm) thick MgO boards with 6 inch (15.24 cm) wide joining strips are used to join together the structural building panels 211 of the first structural layer 210 / bottom floor 304, and 0.5 inch (1.27 cm) thick MgO boards with 6 inch (15.24 cm) wide joining strips are used to join together the structural building panels 216 of the second structural layer 215 / top floor 302. The foam panels 214 / floor foam panels 314 may be 11.25 inches (28.575 cm) thick, making the floor section 300 approximately 12 inches (30.48 cm) thick.

[0116] 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.

[0117] Referring to the Type 1 structure 151 shown in FIG. 6B, the floor section 300a is fixed in place relative to the first wall section 200b-1 of the short wall member 200b and the long wall member 200a-R, and is joined to the floor section 300b using a hinge structure to allow the floor section 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 section 300b is oriented substantially vertically as shown in FIG. 3A, and a fully unfolded position as shown in FIGS. 6A and 6B.

[0118] Similarly, with reference to the Type 2 structure 152 shown in Figure 7A, floor section 300a is fixed in place relative to first wall section 200s-1, fourth wall section 200s-4, and wall member 200s-R. Floor section 300a is joined to floor section 300b using hinge structures similar to those described above in connection with the Type 1 structure 151.

[0119] The hinge structure joining floor sections 300a and 300b can be surface-mounted or recessed, and can be temporary or permanent. Suitable hinge structures can be fabricated, for example, from metal, plastic, leather, ferrous materials, or non-ferrous materials. An example of a suitable hinge structure and its associated components is shown in FIG. 8. In particular, as shown edge-on in FIG. 8, a plurality of steel hinges 306, e.g., 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. Such hinges are commercially available from McMaster-Carr, Douglasville, Georgia, USA. The hinge structure joining floor sections 300a and 300b need not be a double hinge. This is because the hinge structure only needs to pivot through approximately 90 degrees of arc, and therefore the possibility of crimping of the inclusions is less than with the ceiling portion of the ceiling member 400 .

[0120] As shown in Figure 8, each opposing leaf of hinge 306 is secured to an inner edge stiffener, stiffener board 307, provided on each of inner edges 301a and 301b. The stiffener boards 307 in Figure 8 are made from laminated strand timber. Each stiffener board 307 is positioned against the exterior of a web of C-channel tracks 308 (made from cold-formed steel), which are secured to the abutting edges of each of floor sections 300a and 300b, as shown in Figure 8.

[0121] In another aspect, suitable hinge structures for joining floor sections 300a and 300b are described in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Foldable Building Structures with Utility Channels and Laminate Enclosures," filed on the same day and with the same inventor as the present application. The contents of U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which has the same inventor and filing date as the present application, are incorporated herein by reference in their entirety, including, for example, the hinge structures described in paragraphs 125-157 and shown in Figures 13A-15, and more particularly, the hinge structures described in paragraphs 125-135 and shown in Figures 13A-13F. These hinge structures can be used in addition to or instead of the inner edge reinforcement, as described above, and can also perform a sealing function to prevent water intrusion and environmental exposure.

[0122] Baseboard and peripheral board The outer edge of the floor member 300 or portion thereof, such as the outer edge of floor portion 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 floor portion 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.

[0123] Floor Chase If desired, the floor foam panels 314 in the floor section 300 may be provided with a floor chase 319 .

[0124] Figure 7F provides a segmented floor section 300 illustrating an exemplary floor chase arrangement. While shown in Figure 7F for a Type 2 floor section 300, the floor chase 319 can also be utilized with a Type 1 floor section 300, or with floor sections 300 of any other structure 150 manufactured in accordance with the present disclosure.

[0125] As shown in Figure 7F, a first plurality of elongated cylindrical passages, or floor chases 319, are provided, spaced at regular intervals over the entire distance between the first and second lateral floor edges 120, 118 and disposed generally parallel to a first direction, which is generally parallel to the first and second lateral floor edges 120, 118 and generally parallel to each other. Each such floor chase 319 spans the distance between foundation beams 320 disposed proximate the first and second longitudinal floor edges 117, 119, respectively. A second plurality of floor chases 319 are also provided, spaced at regular intervals over the entire distance between the first and second longitudinal floor edges 117, 119 and disposed in a second direction, which is generally perpendicular to the first direction and generally parallel to the first and second longitudinal floor edges 117, 119 and generally parallel to each other. Each such floor chase 319 spans the distance between foundation beams 320 located proximate first and second lateral floor edges 120 and 118, respectively. The first and second plurality of spaced-apart floor chases 319 thus form a floor chase grid. Providing floor chase 319 facilitates routing utility lines (such as power, lighting control, HVAC, HVAC control, and security systems including energization and communication for smoke or heat sensors) from wall component 200 to locations distal to floor member 300. Floor chase segments within the two floor sections of floor member 300 are aligned for communication when floor sections 300a and 300b are fully placed to form completed floor member 300.

[0126] Each floor chase 319 preferably has a diameter sufficient to allow for the installation of utility lines, e.g., about 1-2 inches (2.54-5.08 cm) in diameter. If one or more floor chases 319 are intended for use in the discharge of gray or black water, they preferably have a diameter suitable to accommodate the discharged gray or black water, e.g., greater than about 4 inches (10.16 cm), e.g., about 6 inches (15.24 cm), with appropriate slope. The floor chases 319 may be formed in the floor foam panels 314 by using a circular hot wire that is appropriately positioned and run into the foam panel below the surface of the panel, in generally the same manner as described above for the wall chases.

[0127] Preferably, the floor chases 319 are positioned so as to be aligned with and in communication with the wall chases 219 within the wall member 200. Thus, for example, if the wall chases 219 are spaced approximately 29 inches (73.7 cm) apart, then the floor chases are preferably also spaced approximately 29 inches (73.7 cm) apart. In the manner shown in Figures 7A-7B, each floor chase 319 intersects and communicates with a vertically oriented passageway, floor chase connector 372, which in turn communicates with the respective wall chase 219 via through-holes 291 in the floor plate 220 of the wall member 200. This arrangement therefore provides each of the floor chases 319 with routing access to the utility lines to the respective wall chase 219 and subsequently to the utility service system 460 (in-situ channel 471, in the particular embodiment shown) and ceiling chase 440. In a similar manner as described above with respect to the wall chase 219, cutout openings can be formed in the floor member 300 to communicate with the floor chase 319, thereby, for example, providing access to electrical services across the floor member 200 at multiple locations.

[0128] Enclosure component relationships 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 .

[0129] Figure 2A shows a schematic top view of the Type 1 structure 151 shown in Figure 1A, with a geometric orthogonal grid to clarify the description of 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.

[0130] 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 is 24E in length and 4E in width. The two floor sections 300a and 300b of Type 1 structure 151 are shown in Figures 2A and 3A. Each of the floor members 300a and 300b is 24E in length, while floor member 300a is approximately 4E in width and floor member 300b is approximately 8E in width.

[0131] The shipping module 100 of the Type 1 structure 151, shown edge-forward 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 inward and positioned against the fixed space portion 102 (identified as wall portions 200b-2f in FIG. 2A when so folded and positioned). The three ceiling portions 400a, 400b, and 400c of the Type 1 structure 151 are shown unfolded in FIG. 1A. 3A, which illustrates the shipping module 100 of the Type 1 structure 151, shows ceiling members 400b and 400c stacked on top of ceiling member 400a, which partially defines fixed space portion 102. Long wall member 200a-P, shown in FIGS. 2A and 3A, is pivotally fixed to floor portion 300b at the location of horizontal axis 105 and positioned vertically adjacent to the outside of second wall portion 200b-2. Floor portion 300b is also positioned vertically proximal to fixed space portion 102, with long wall member 200a-P suspended (i.e., hung) from floor portion 300b between floor portion 300b and second wall portion 200b-2.

[0132] Sizing the enclosure members 155 of 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, shipping module 100, when sized according to the relationships disclosed herein using an "E" dimension (see FIG. 2A) of approximately 19.5 inches (49.5 cm), and with its members stacked and positioned as shown in FIG. 3A, 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.

[0133] 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 overlaid orthogonal grid in Figure 2B is approximately 8E and 8E in length.

[0134] 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 is 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 is 8H in length, while floor section 300a is approximately 3E in width and floor section 300b is approximately 5E in width.

[0135] Shipping module 100 of Type 2 structure 152, shown edge-forward in Figure 3B, also generally has fixed space portion 102 defined by ceiling member 400a, floor member 300a, wall member 200s-R, wall portion 200s-1, and wall portion 200s-4. As shown in Figure 2B, second wall member 200s-2 is folded inward and positioned generally against fixed space portion 102, while third wall portion 200s-3 is folded outward and positioned generally against 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 unfolded in FIG. 1B. FIG. 3B, which illustrates the shipping module 100 of the Type 2 structure 152, shows ceiling members 400b and 400c stacked on top of ceiling member 400a, which partially defines the fixed space portion 102. 2B and 3B, wall member 200s-P is pivotally fixed to floor portion 300b at the location of axis 105 and positioned vertically adjacent to the outside of wall portions 200s-3 and 200s-5. Floor portion 300b is also positioned vertically proximal to fixed space portion 102, with long wall member 200s-P suspended from floor portion 300b between floor portion 300b and wall portions 200s-3 and 200s-5.

[0136] 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.

[0137] 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 will be easily positioned during construction completion.

[0138] Preferably, the fixed volume portion 102 is relatively complete before all other wall, ceiling, and floor sections are positioned (folded) together as described above. That is, the fixed volume portion 102 is preferably fitted during manufacturing with all mechanical and other functions required by the structure 150, such as a kitchen, bathroom, laundry room, HVAC closet, fireplace, clothing 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 (comparisons of the Type 2 structure 152 do not utilize equivalent temporary members for shipping). Preferably, once the fixed volume portion 102 is completed to the desired state, the remaining members are folded and positioned against the fixed volume 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.

[0139] As exemplified by the long wall member 200a in FIG. 5A, each of the wall members 200, floor members 300, and ceiling members 400, and / or portions thereof, can be coated with a protective film 177 during manufacturing and prior to the formation of the shipping module 100. Alternatively, or in addition, the entire shipping module 100 can be coated with a protective film. These protective films thus constitute a means for protecting the shipping module 100 and 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 members' resistance to bending and torsional stresses that may occur during transportation of the members. These protective films also provide rigidity to the wall member 200, further improving its robustness during transportation and the construction of the structure at the construction site. Preferably, such protective films remain in place until after the shipping module 100 arrives at the construction site, where they are then removed as needed to facilitate the deployment and completion of the enclosure members.

[0140] Shipping Module Transportation The shipping module is shipped to the construction site by suitable transportation. One such transportation 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 0020-0035 and shown in Figures 1A-2D, are incorporated herein by reference in their entirety. As an alternative transportation method, the shipping module 100 can be shipped to the construction site using a conventional truck trailer or a lowbed trailer (also known as a lowboy trailer).

[0141] Deployment and completion of the structure At the building site, shipping module 100 is positioned at its desired location, for example, over a prepared foundation, such as a cast-in-place concrete slab, a cast-in-place concrete or cinder block foundation, a deck beam, or a concrete pillar or column. This can be accomplished by using a crane to lift shipping module 100 from its transportation vehicle and move it to the desired location, or by positioning the transportation vehicle over the desired location, lifting shipping module 100, then moving the transportation vehicle from the desired location, and then lowering shipping module 100 to rest at the desired location. Particularly suitable equipment and techniques for facilitating positioning of 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 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, are incorporated herein by reference as if fully set forth, specifically including, for example, the equipment and techniques described in paragraphs 126-128 and in connection with Figures 11A and 11B.

[0142] After positioning the shipping module 100 at the construction site, the appropriate portions of the wall section 200, floor section 300 and ceiling section 400 are "unfolded" (i.e., unfolded) in the sequence described above to provide the completed structure 150.

[0143] 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 its deployed position, (2) wall members 200a-P are pivotally rotated about horizontal axis 305 shown in Figure 3A to its deployed position, (3) wall portion 200b-2 of short wall member 200b is pivotally rotated about vertical axis 191 shown in Figure 2A to its deployed position, and (4) ceiling portions 400b and 400c are pivotally rotated about horizontal axes 405a and 405b, respectively, to their deployed positions.

[0144] For Type 2 structure 152, deployment occurs in the following order: (1) floor section 300b is pivotally rotated about horizontal axis 305 shown in Figure 3B to the deployed position, (2) wall member 200s-P is pivotally rotated about horizontal axis 105 shown in Figure 3B (behind perimeter board 312) to the deployed position, (3) wall sections 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 sections 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 deployment of certain enclosure members 155, specifically ceiling sections 400b and 400c, floor section 300b, and wall members 200 pivotally secured to floor section 300b (200a-P for Type 1 structure 151 and 200s-P for Type 2 structure 152). In another aspect, particularly suitable equipment and techniques for facilitating the deployment 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 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, specifically including, for example, the equipment and techniques described in paragraphs 132-145 and in Figures 12A-14B, are incorporated herein by reference as if fully set forth.

[0145] In particular, the baseboard 310, in an appropriate location, functions as a "blocker" that prevents the wall member or wall section from unfolding in its intended deployed position. Thus, for example, the baseboard 310 in FIG. 3A , showing Type 1 structure 151, prevents the unfolding of the long walls 200 a-P shown in that figure when the long walls 200 a-P are fully unfolded in their desired vertical positions. Similarly, the perimeter board 312 in FIG. 3B , showing Type 2 structure 152, performs a similar function for wall 200 s-P and for wall sections 200 s-2, 200 s-3, and 200 s-5. Furthermore, the baseboard 310 provides a structure for securing the unfolded wall member in its unfolded position. Thus, for example, the baseboard 310 in FIG. 6A is provided with a plurality of spaced openings 311 through which fasteners can be inserted to secure the long wall 200 a in place.

[0146] 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. When certain portions of the enclosure component perimeter structures disclosed in U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which shares the same inventor and filing date as the present application, are utilized, particularly those portions described in paragraphs 121-157 and shown in Figures 12-15, for example, certain finishing operations are preferably performed on such structures, as described herein. The contents of U.S. Non-Provisional Patent Application No. 16 / 786,202, entitled "Enclosure Component Perimeter Structures," which has the same inventor and filing date as the present application, are incorporated herein by reference as if fully set forth herein, including, for example, the finishing operations performed on the enclosure component perimeter structures described in paragraphs 179-182 thereof and shown in Figures 13C, 13F, 14C, 14E, 15, and 17.

[0147] After deployment and securing of enclosure member 155, one or more preselected chases located on wall member 200 (connecting and vertical wall chases 207 and 219), floor member 300 (floor chase 319), and ceiling member 400 (ceiling chase 440) can be routed and connected to appropriate utility lines in utility channel 460, such as electrical loop 208, as described above. This also allows loop 208 to connect to an electrical utility service drop, thus energizing electrical service for the completed structure 150.

[0148] Before, during, or after deployment and fastening of enclosure member 155, one or more door and window openings 202, 204 are cut in the wall member 200 at desired locations, as desired, 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.

[0149] Building Configuration Options As noted above, any number of structures 150 can be arranged together at a desired location or site, resulting in many different structural configurations. Internal staircases for such multi-level structures can be provided in the fixed volume portions 102 during manufacture, or added after assembly, with appropriate access openings inserted in the ceiling members 400. Similarly, sloped roofs and other architectural additions can be delivered separately from the shipping modules 100 or fabricated on-site and placed on the ceiling members 400 of the completed structure 150.

[0150] For example, two or more completed structures 150 can be erected such that wall members 200 of one structure are positioned adjacent to wall members 200 of another structure. The builder can then cut openings in these juxtaposed areas to connect the two structures according to the purchaser's design preferences. As an example, FIG. 10 shows a floor plan of three completed structures 150a, 150b, and 150c, each a Type 2 structure 152, placed side by side to create a single housing unit with three rooms. The stacked, multi-layer design of the enclosure members 155 provides flexibility in placement, in this particular example, allowing for the placement of window openings 204 in each wall member 200, thereby providing windows on all four sides of each room.

[0151] Completed structures 150 can also be stacked one on top of the other to create a multi-story structure. FIG. 11 shows completed structure 150e, using two Type 2 structures 152 and placed atop completed structure 150d to create a two-story structure. The laminated multi-layer design of enclosure components 155 allows for a wide variety of customization options. Thus, as shown in FIG. 10, a garage opening 203 is provided in addition to the first-level door opening 202, as well as a second-level door opening 202 (not shown) accessed via an exterior staircase 201. Furring strips or furring strips 418 may be provided on the ceiling top surface 402 along the first and second longitudinal ceiling edges 406 and 416, along the second and first lateral ceiling edges 408 and 410, and at selected intervals within the perimeter of those edges, as needed. Such furring strips 418, shown in FIG. 6C, provide an air barrier between levels of the multi-layer structure. If desired, means may be utilized to secure the stacked completed structures 150 together, such as by using rebar plates secured at separate locations to connect the upper floor members 300 to the lower ceiling members 400.

[0152] When four or more complete structures 150 are stacked in a 2x2 array, their baseboards 310 (shown in FIG. 6A ), if utilized in appropriate locations, abut one another, thereby providing space between the stacked complete structures 150. For example, the baseboards 310 may be approximately 2 inches (5.08 cm) thick (in the dimension parallel to the floor members 300). Such a thickness provides space between adjacent complete structures 150, which are approximately 4 inches (10.16 cm) wide, and can be utilized to route utility lines between floors, such as piping stacks (vertical mains used for liquid waste discharge) or electrical mains. Such utility lines can be accessed as needed by forming openings in the shoulder beams 435 at appropriate locations.

[0153] The foregoing detailed description is for purposes of illustration only and is not to be construed as limiting the invention, the invention being defined in the appended claims.

Claims

1. A foldable architectural structure, comprising: a fixed space portion, the fixed space portion having a first floor portion having a thickness defining an interior portion thereof, a first ceiling portion having a thickness defining the interior portion thereof, and a first wall portion having a thickness defining the interior portion thereof; The foldable architectural structure further comprises: a second ceiling portion having a thickness defining an interior portion thereof, the second ceiling portion being movable between a folded position proximal to the fixed space portion and an unfolded position; a third ceiling portion having a thickness defining an interior portion thereof, the third ceiling portion being movable between a folded position proximal to the fixed space portion and an unfolded position; the second and third ceiling portions are movable from their respective folded positions to their respective extended positions to form a ceiling member of the architectural structure together with the first ceiling portion in their extended positions, and the ceiling member has a periphery; at least one of the first ceiling portion, the second ceiling portion, and the third ceiling portion includes at least a portion of a closed-loop passageway adjacent the periphery within the interior portion adapted to accommodate a utility line; Foldable architectural structure.

2. the first, second, and third ceiling portions each define a section of a closed-loop passageway within the interior portion of the first, second, and third ceiling portion; 2. The foldable architectural structure according to claim 1.

3. A foldable architectural structure, comprising: a fixed space portion, the fixed space portion having a first floor portion having a thickness defining an interior portion thereof, a first ceiling portion having a thickness defining the interior portion thereof, and a first wall portion having a thickness defining the interior portion thereof; The foldable architectural structure further comprises: a second ceiling portion having a thickness defining an interior portion thereof, the second ceiling portion being movable between a folded position proximal to the fixed space portion and an unfolded position; a third ceiling portion having a thickness defining an interior portion thereof, the third ceiling portion being movable between a folded position proximal to the fixed space portion and an unfolded position; the second and third ceiling portions are movable from their respective folded positions to their respective extended positions to form a ceiling member of the architectural structure together with the first ceiling portion in their extended positions, and the ceiling member has a periphery; at least one of the first floor portion, the first ceiling portion, the second ceiling portion, and the third ceiling portion includes at least a portion of a closed-loop passageway adjacent the periphery within the interior portion adapted to accommodate utility lines; the first, second, and third ceiling portions each define a section of a closed-loop passageway within the interior portion of the first, second, and third ceiling portion; the sections of the closed loop passageway within the first, second, and third ceiling sections form a closed loop within the interior portions of the ceiling sections when the second and third ceiling sections are in their deployed positions, the closed loop being positioned proximate the periphery of the ceiling member and adapted to accommodate the utility line; the first ceiling portion having a first plurality of spaced apart elongated ceiling chases for accommodating utility lines within an interior portion thereof; the second ceiling portion having a second plurality of spaced apart elongated ceiling chases for accommodating utility lines within an interior portion thereof; the third ceiling portion having a third plurality of spaced apart elongated ceiling chases for accommodating utility lines within an interior portion thereof; one or more of the first plurality of spaced apart elongated ceiling chases, one or more of the second plurality of spaced apart elongated ceiling chases, and one or more of the third plurality of spaced apart elongated ceiling chases are in communication with the closed loop passage formed when the second and third ceiling sections are in their deployed positions and together with the first ceiling section form the ceiling member of the architectural structure; at least one channel access opening formed in a first ceiling portion, said at least one channel access opening being located in said first ceiling portion proximate an intersection of a first plurality of spaced apart elongated ceiling chases and said closed-loop path; Foldable architectural structure.

4. further comprising a foam material within the interior portions of the first, second, and third ceiling portions, and the closed-loop passage is disposed within the foam material of the first, second, and third ceiling portions. A foldable architectural structure according to claim 3.

5. the closed loop passage has a first channel and a second channel spaced from and substantially parallel to the first channel; the first channel and the second channel have a substantially circular cross section; A foldable architectural structure according to claim 4.

6. each of the first ceiling portion, the second ceiling portion, and the third ceiling portion having a plurality of spaced apart elongated ceiling chase segments in an interior portion thereof, the interior portions adapted to form a fourth plurality of spaced apart elongated ceiling chases for accommodating utility lines; and a second and third roof portion communicating with the closed loop passage formed when the second and third roof portions are in their deployed positions; the fourth plurality of spaced apart elongated ceiling chases being oriented in a substantially perpendicular direction to the first, second, and third plurality of spaced apart elongated ceiling chases; A foldable architectural structure according to claim 3.

7. a second wall portion having a thickness defining an interior portion thereof, the second wall portion being movable between a folded position proximal to the fixed space portion and an unfolded position, and in the unfolded position forming all or part of a wall member of the architectural structure together with the first wall portion; the first wall portion having a first plurality of spaced apart elongated wall chases for accommodating utility lines within an interior portion thereof; the second wall portion having a second plurality of spaced apart elongated wall chases for accommodating utility lines within an interior portion thereof; and one or more of the first spaced apart elongated wall chases and one or more of the second spaced apart elongated wall chases are in communication with the closed loop passageway formed when the second and third wall portions are in their deployed positions to form, together with the first ceiling portion, the ceiling member of the architectural structure. A foldable architectural structure according to claim 3.

8. the first wall portion and the second wall portion have wall chase segments within their interior portions, the wall chase segments adapted to form a connecting wall chase for containing a utility line when the first wall portion is in its deployed position, the connecting wall chase communicating with each of the first and second spaced apart elongated wall chases when the first wall portion is in its deployed position; A foldable architectural structure according to claim 7.

9. a thickness defining an interior portion of the second floor member, the second floor member being movable between a folded position proximate to the fixed space portion and an unfolded position in which the second floor member forms a floor member of the architectural structure together with the first floor member; the first floor section having a first plurality of spaced apart elongated floor chases at an interior portion thereof for accommodating utility lines; the second floor section having a second plurality of spaced apart elongated floor chases at an interior portion thereof for accommodating utility lines; one or more of the first plurality of spaced apart elongated floor chases and one or more of the second plurality of spaced apart elongated floor chases are in a communicating relationship with a first and a second elongated wall chase of each of the first plurality of spaced apart elongated wall chases and / or the second plurality of spaced apart elongated ceiling chases when the second wall portion is in its extended position and together with the first wall portion forms all or part of a wall member of the architectural structure, and when the second floor portion is in the extended position and together with the first floor portion forms all or part of the floor member of the architectural structure. A foldable architectural structure according to claim 7.

10. each of the first floor section and the second floor section having a plurality of spaced-apart, elongated floor chase segments at an interior portion thereof adapted to form a third plurality of spaced-apart, elongated floor chases for accommodating utility lines when the second floor section is in its deployed position, the third plurality of spaced-apart, elongated floor chases being oriented in a direction substantially perpendicular to the first and second plurality of spaced-apart, elongated floor chases; 10. A foldable architectural structure according to claim 9.

Images