Enclosed structures constructed using component construction

Abstract

A method for manufacturing component construction includes producing a plurality of side panels for a structure, and constructing at least one coupling point for each side pane of the plurality of side panels. The plurality of side panels is produced to be a predetermined size, and the predetermined size is compatible to fit a floor assembly. The at least one coupling point couples to predetermined location of the floor assembly, and the at least one coupling point for each side panel is constructed to couple the at least one coupling point of each side panel to the floor assembly at the location of the construction.

Description

ENCLOSED STRUCTURES CONSTRUCTED USING COMPONENT CONSTRUCTIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63 / 584,838 filed on September 22, 2023 and entitled, “Enclosed Structures Constructed Using Modular Construction,'’ which is incorporated herein by reference in its entirety.BACKGROUND

[0002] Various structures can be used to provide an accommodation. The structures are typically purpose built using raw materials including lumber, siding, and connectors. Each structure can be unique due to the extensive effort needed to construct the structure. Even when building kits are available, the kits typically contain the appropriate amount of raw materials that can then be assembled into a building structure using traditional construction techniques. Once constructed, the structure is essentially permanent and cannot be disassembled such that the structure could be rebuilt or constructed elsewhere and retain its structural stability.SUMMARY

[0003] In some embodiments, a method for manufacturing component construction comprises producing a plurality of side panels for a structure, and constructing at least one coupling point for each side panel of the plurality of side panels. The plurality of side panels is produced to be a predetermined size, and the predetermined size is compatible to fit a floor assembly. The at least one coupling point couples to predetermined location of the floor assembly, and the at least one coupling point for each side panel is constructed to couple the at least one coupling point of each side panel to the floor assembly at the location of the construction.

[0004] In some embodiments, a kit for constructing an enclosed structure comprises a plurality' of support frames for a floor assembly, a plurality of side panels, and an interior covering coupled to the side panel support frame, and a plurality of roof trusses. The side panels can each comprise a side panel support frame.

[0005] In some embodiments, an enclosed structure comprises a floor assembly comprising a plurality of support frames coupled together and a floor placeable upon the plurality of support frames, a plurality of side panels, and a roof assembly disposed on and coupled to the plurality of side panels. Each side panel of the plurality of side panels is coupled to an adjacent side panel to form an exterior wall.

[0006] In some embodiments, a method of constructing an enclosed structure comprises coupling a plurality of support frames together to form a floor assembly, disposing a floor to the plurality of support frames, coupling a plurality of side panels together on top of the floor, couplingthe plurality of side panels to the floor assembly, and disposing a roof assembly on the exterior wall and coupling the roof to the plurality of side panels. Each side panel of the plurality of side panels is coupled to an adjacent side panel to form an exterior wall.

[0007] These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

[0009] FIG. 1 is a perspective view of an enclosed structure according to an embodiment of the disclosure.

[0010] FIG. 2 is a perspective view of a floor assembly according to an embodiment of the disclosure.

[0011] FIG. 3 is a perspective view of a floor assembly being partially constructed according to an embodiment of the disclosure.

[0012] FIG. 4 is a perspective view of a floor assembly being partially constructed according to an embodiment of the disclosure.

[0013] FIG. 5 is a perspective view of a completed floor assembly according to an embodiment of the disclosure.

[0014] FIG. 6 is a side view of a side panel according to an embodiment of the disclosure.

[0015] FIG. 7 is a side view of a side panel that is partially constructed according to an embodiment of the disclosure.

[0016] FIG. 8 is a side view of a side panel that is completed according to an embodiment of the disclosure.

[0017] FIG. 9 is a top view of a roof assembly that is partially constructed according to an embodiment of the disclosure.

[0018] FIG. 10 is another top view of a roof assembly that is partially constructed according to an embodiment of the disclosure.

[0019] FIG. 11 is still another top view of a roof assembly that is partially constructed according to an embodiment of the disclosure.

[0020] FIG. 12 is yet another top view of a roof assembly that is partially constructed according to an embodiment of the disclosure.

[0021] FIG. 13 is a top view of a roof assembly that is partially constructed according to an embodiment of the disclosure.

[0022] FIG. 14 is a top view of a roof assembly that has a decking constructed according to an embodiment of the disclosure.

[0023] FIG. 15 is a perspective view of a foundation for an enclosed structure that is partially constructed according to an embodiment of the disclosure.

[0024] FIG. 16 is a perspective view of a foundation with a floor assembly for an enclosed structure that is partially constructed according to an embodiment of the disclosure.

[0025] FIG. 17 is a perspective view of a foundation, floor assembly, and side panels for an enclosed structure that is partially constructed according to an embodiment of the disclosure.

[0026] FIG. 18 is a perspective view of a foundation, floor assembly, side panels, and interior walls for an enclosed structure that is partially constructed according to an embodiment of the disclosure.

[0027] FIG. 19 is a perspective view of a foundation, floor assembly, side panels, interior walls, and a roof assembly for an enclosed structure that is partially constructed according to an embodiment of the disclosure.

[0028] FIG. 20 is a perspective view of a completed enclosed structure according to an embodiment of the disclosure.

[0029] FIG. 21 is a perspective view of a foundation, floor assembly, side panels, interior walls, and a roof assembly for another enclosed structure that is partially constructed according to an embodiment of the disclosure.

[0030] FIG. 22 is a perspective view of another completed enclosed structure according to an embodiment of the disclosure.

[0031] FIG. 23 is a perspective view of a partially constructed two-slory enclosed structure according to an embodiment of the disclosure.

[0032] FIG. 24 is a perspective view of a partially constructed two-story enclosed structure with interior walls according to an embodiment of the disclosure.

[0033] FIG. 25 is a perspective view of another completed enclosed structure according to an embodiment of the disclosure.DETAILED DESCRIPTION

[0034] It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below; the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

[0035] This disclosure pertains to enclosed structures which may be utilized for a variety of purposes upon completion of their construction. For example, the enclosed structures may be utilized as a house or living space, an office, a storage unit, an entertainment room, or for other purposes. The enclosed structures may include access to one or more utilities (e.g., electrical utilities, water, sewer, heating / air conditioning, etc.) to grant a user of the structure access to said utilities while within the structure. Additionally, the enclosed structures may be assembled at a variety of locations for only a limited period of time before disassembly and transport to another location. The enclosed structures may be considered permanent structures on a permanent foundation while constructed, even while being dissembled and moved at a later time.

[0036] Embodiments disclosed herein include enclosed structures that may be used for a variety of purposes such as a house, an office, a storage unit, an entertainment room or unit, etc. The enclosed structures may include utilities, such as electrical outlets and an air conditioner to provide further utility to the structure. The enclosed structures described herein are configured to be assembled with a minimum amount of tooling, making the disclosed enclosed structures relatively easy to assemble and disassemble.

[0037] Additionally, embodiments of enclosed structures disclosed herein may comprise prefabricated components that can be packaged and shipped in specific combinations or kits, thereby allowing structures having a variety of dimensions and square footage to be assembled from the components while maintaining a minimum inventory for the manufacturer or supplier of the structures. In some contexts, this can be referred to as component construction. Further, a limited number of components may be maintained to be used for the floor or foundation, the walls (interior and exterior), and the roof. While a limited number of components may be used, a wide variety of structures and floorplans can be constructed from the components. For example, an enclosed structure having a size of 10 feet (ft) by 10 ft providing 100 square ft of space may comprise one or more components that may be used to assemble an enclosed structure having a size of, for example, 10 ft by 20 ft to provide a square footage of 200 ft. Given that the two differently sized enclosed structures may share common components, the inventory7required to supply these two separate structures may be minimized. Additionally, a purchaser of an enclosed structure having a first square footage may be able to purchase one or more additional components to reconfigure the structure to have a second square footage without needing to purchase an entirely new enclosed structure. In the event that the structure is to be removed, the components can be disassembled and stored as components, which may make long term storage of the structures easier and more convenient. Further, the storage of new or disassembled components may allow for the structures to be staged in different locations in the event that the structures are needed on short notice. Forexample, in the event of an emergency such as a hurricane, the component can be used to construct housing for those affected by the storm, and after the housing need passes, the structures can be disassembled and stored for the next emergency.

[0038] Turning now to FIG. 1, an enclosed structure 100 is described. In an embodiment, the enclosed structure 100 generally comprises a plurality of panels including a floor assembly 102 positioned on a foundation 103, a plurality of first side panels 120, a second side panel 140, and a roof assembly 200 (e.g., as shown in FIG. 9). The enclosed structure 100 may comprise a kit that can be shipped as a set of floor panels, side panels, and roof panels to be assembled and thus may also be referred to herein in some aspects as a kit 100 for assembling an enclosed structure.

[0039] As shown in FIG. 1, the floor assembly 102 can be positioned on a foundation 103. The foundation can comprise any suitable structure to support the floor assembly 102. In some aspects, the foundation 103 can comprise a permanent foundation and / or can form a structural foundation. FIG. 1 illustrates the use of a ground support (e.g., a ground screw) that can be placed into the ground and leveled to form a permanent foundation. Any other suitable foundations can also be used such as steel, helical, wooden, concrete, stone piers and / or slabs, or the like. Any other type of supports such as a concrete and / or masonry footing wall could also be used in some aspects. As described in more detail herein, the foundation 103 can be coupled to and support the floor assembly 102 using various connection points.

[0040] Referring to FIG. 2, the floor assembly 102 of an enclosed structure 100 may comprise one or more support frames 104A, 104B, 104C and a floor 115 (e.g.. as shown in FIG. 5). While three support frames 104A, 104B, and 104C are shown, less than three (e g., one or two) or more than three support frames can be used as part of the enclosed structure 100. Each support frame 104A, 104B, 104C may comprise an exterior rectangular or box-frame 105 and a plurality of elongate supports 107 positioned in the box-frame 105 and configured to provide support to the respective support frame 104A, 104B, 104C. In some embodiments, the box-frame 105 of each support frame 104A, 104B, 104C may comprise four elongate members or supports coupled together (e.g., welded, bolted, etc.) to form the box-frame 105. In some embodiments, the boxframe 105 and supports 107 of each support frame 104 A. 104B, 104C may comprise a plurality of elongate steel beams; however, in other embodiments, the configuration of each support frame 104 A, 104B may vary.

[0041] Each support frame 104A, 104B, 104C may comprise a first or upper surface 106 and a second or lower surface 108 opposite the upper surface 106. In an embodiment, each support frame 104 A, 104B. 104C of floor assembly 102 may include a plurality of connection points 110 coupled to the lower surface 108 of the respective box-frame 105. Particularly, a first supportframe 104A of floor assembly 102 may comprise four connection points 110 located at the four comers of the box-frame 105 of first support frame 104 A. A second support frame 104B of floor assembly 102 may be couple to the first support frame 104 A and share a connection point 110 at the comers where the first support frame 104 A and the second support frame 104B meet. The connection points 110 can be configured to couple to and be supported by the foundation 103. For example, each connection point 110 can be supported by a foundation 103 such as a pier either directly or through a spacer such that the floor assembly 102 can be leveled on the foundation 103. In some aspects, the plurality of support frames 104A, 104B, 104C can be coupled to the foundation 103. For example, the support frames 104A, 104B, 104C can be welded, screwed, bolted, or otherwise attached to the foundation 103 to prevent the floor assembly 102 from lifting or sliding off of the foundation 103.

[0042] Rather than including connection points 110 at each comer of the box-frame 105 of second support frame 104B, an inner edge 112 of the box-frame 105 of second support frame 104B may be configured to couple with a corresponding inner edge 112 of the box-frame 105 of fist support frame 104 A, via. for example, one or more releasable fasteners. In this manner, the two connection points 110 positioned along the edges of the box-frame 105 of the first support frame 104 A may support the center of floor assembly 102. In other embodiments, support frame 104B may comprise four connection points 110 positioned at the comers of box-frame 105 and boxframes 105 of support frames 104A, 104B may not be coupled together during the assembly of floor assembly 102.

[0043] As shown in Figure 2 the support frames 1 4 A, 1 4B, 104C can be coupled together using various fasteners such as bolts 112, pins, or other connectors, or in some aspects, welds, to couple the plurality of support frames together. The floor assembly 102 can also comprise one or more channels to allow for electrical conduits 116 to be connected between external electrical boxes 113 and electrical receptacles 117 (e.g., outlets) positioned to be accessible in the enclosed structure 100. In some aspects, the support frames 104A, 104B, 104C can be prepared and shipped as components comprising the box-frames 105, the elongated supports 107, and the channels with electrical components pre-installed. This can allow for the foundation connections and the electrical connections to be inspected prior to completing and sealing the floors, where such inspections can be required in various locations.

[0044] In some aspects, the floor assembly 102 and / or support frames 104A, 104B, 104C may have a smaller dimension (e.g., a width) of at least about 2 feet, at least about 4 feet, at least about 6 feet, at least about 8 feet, at least about 10 feet, or at least about 12 feet. The smaller dimension may be less than about 25 feet, less than about 20 feet, less than about 18 feet, less than about 16feet, less than about 14 feet, less than about 12 feet, less than about 10 feet, less than about 8 feet, or about 6 feet. In some aspects, the floor assembly 102 and / or support frames 104A, 104B, 104C may have a larger dimension (e.g., a length) of at least about 4 feet, at least about 6 feet, at least about 8 feet, at least about 10 feet, at least about 12 feet, or at least about 15 feet. The larger dimension may be less than about 50 feet, less than about 40 feet, less than about 35 feet, less than about 30 feet, less than about 25 feet, less than about 20 feet, less than about 15 feet, or about 12 feet. In some aspects, the floor assembly 102 and / or support frames 104 A, 104B, 104C can have a ratio of the length (e g., the larger dimension) to the width (e.g., the smaller dimension) of between about 4:1 to about 1: 1, between about 3: 1 to about 1.2: 1, between about 2.5: 1 to about 1.5: 1, or about 2:1.

[0045] The process of installing the floor assembly 102 can be seen with reference to FIGS. 2-5. As shown in FIG. 2, the plurality of support frames 104 A, 104B, 104C can be coupled together and supported on the foundation 103. A bottom sheath 119 can positioned below and in contact with the lower surface 108 of the box frames 105 of support frames 104A, 104B. 104C. The bottom sheath 119 can be coupled to the floor assembly 102 to serve as a weather barrier and prevent water ingress into the enclosed structure 100. The bottom sheath 119 can comprise any suitable water and weather resistant material such as siding, metal, plastic, or the like. The bottom sheath 119 can form a seal with respect to the plurality' of support frames 104 A, 104B, and 104C to form a water barrier.

[0046] An insulating layer can then be formed or placed into the support frames 104A, 104B, 104C to insulate the floor assembly 102. As shown in FIG. 4, the insulation 120 can be positioned within the support frames 104A, 104B, 104C, and may extend between the bottom sheath 119 and an upper surface 106 of the box frame 105. The insulation can be formed from roll insulation (e.g., fiberglass, natural fibers, foam sheeting, etc.), spray insulation (e.g., foam. etc ), or combinations thereof. The insulation can be placed around the various supports 107 to while leaving the outlets 117 exposed. In some aspects, the floor assembly 102 can be shipped with the bottom sheath 119 and the insulation pre-installed. The bottom sheath 119 can be opened to allow for the connections to the foundation and then resealed.

[0047] FIG. 5 illustrates the placement of a floor 115 on the support frames 104 A. 104B, 104C. The floor 115 of floor assembly 102 may be positionable on the upper surfaces 106 of the boxframes 104 of the support frames 104A, 104B, 104C. Particularly, floor 115 may have a dimension corresponding or equivalent to the combined dimensions of the box-frames 105 of the support frames 104 A, 104B, 104C. For example, an outer perimeter of the floor 115 may equal or be slightly less than an outer perimeter of the box-frames 105 of the support frames 104 A, 104B,104C following the coupling of box frames 105 during the assembly of floor assembly 102. The floor 115 of floor assembly 102 may comprise any suitable flooring material such as plywood, laminate material, wooden planks, tiles, or the like. Floor 115 may couple with the support frames 104A, 104B, 104C via one or more fasteners (e.g., releasable fasteners, adhesive, etc.) to secure floor 115 to support frames 114A, 114B, 114C. In an embodiment, floor 115 may comprise openings for the plurality of receptacles 117. The electrical outlets 117 can be installed prior to the floor 115 being placed onto the floor assembly, or the outlets 117 can be installed after the floor 115 is put into position.

[0048] A portion of the floor 115 can comprise access panels 118 that can be positioned over the utility channels (e.g., electrical channels, plumbing channels, etc.) to allow for installation and / or inspection of the electrical components once the floor 115 is put into position. The access panels 118 can be removable and replaceable as needed. The access panels 118 may be relatively thin portions of the floor 115 to allow for the utility channels to be accessed during inspection or repairs without the need to remove the majority of the floor 115. In some aspects, the bottom sheath 119 and the floor 115 can be provided as one-piece assemblies for installation on site, and form a part of a kit for being shipped to form the enclosed structure.

[0049] The enclosed structure 100 can also comprise a plurality of side panels. Referring to FIG. 6, each of the side panels 120 of enclosed structure 100 may generally include a support frame 122 positioned between an interior covering or facade 124 and an outer or external covering or facade 126 (e.g.. as shown in FIG. 7). In some embodiments, a layer of insulation such as fiberglass insulation, foam panels, or injectable foam can be disposed between the interior covering or facade 124 and an outer or external covering or facade 126 in order to insulate the final structure. In some embodiments, the support frame 122 may comprise a plurality' of beams, studs, or supports that can be formed from any suitable materials (e.g., steel, wood, etc.). For example, the support frames 122 can be formed from steel beams or from wood (e.g., solid wood, engineered wood beams, mass timber beams, etc.). The plurality' of beams, studs, or supports can be placed on standard spacing (e.g., 16 inch centers, etc.), and double header supports and / or double framing supports for openings can be used. One or more vertical studs can extend through the side panels to provide structural support to the support frame 122. When one or more opening are present, double studs can be used with headers to form the openings with the proper structural support. The support frame 122 can be joined using any suitable mechanical couplings such as nails, screws, bolts, or the like. In some aspects, the mechanical couplings used to form the side panels can comprise screws to allow for a holding force (e.g. a tensile force) between a top and bottom of the support frame 122.

[0050] The support frame can generally be the same size regardless of the use of the side panels 120. For example, as shown in FIG. 6, the side panel 120 can be a door panel 120A, a window panel 120B, or a wall panel 120C. The side panel 120 may include a first aperture 148 and / or a second aperture 150, each aperture 148, 150 extending entirely through the support frame 122 and coverings 124, 126. In an embodiment, the first aperture 148 may comprise a doorframe in which a door may be positioned to form a door panel while second aperture 150 may comprise a window frame in which a window may be positioned to form a window panel.

[0051] Within the support frame 122, one or more couplings can be used to provide tie down support extending betw een a low er edge of the support frame 122 and an upper edge of the support frame. One or more top couplings 141 can be used to provide a fixed mechanical connection between the top support of the support frame, and the vertical studs or headers. One or more lower couplings 142 can be used to provide a fixed mechanical connection between the bottom support frame and a floor and / or one or more support frames w hen installed. The low er couplings 142 can be coupled to a bottom support frame and / or the one or more vertical studs or headers. In some aspects, the lower couplings 142 an be coupled to the same vertical studs as the one or more top couplings 142 to provide a continuous tie down from the lower couplings 142 through the top couplings 141 to directly tie the roof joists to the floor and / or foundation in the final structure. The couplings 141, 142 can be formed from any suitable materials, and in some embodiments, the couplings 141, 142 can be formed from metal strips or straps that can be coupled in a plurality of locations (e.g.. on each end and / or in the middle) to the support frame 122 using mechanical couplings such as screws or nails.

[0052] In some aspects, the lower couplings 142 can connect to the side panel to a floor assembly at one or more predetermined locations. This can allow the floor assembly and side panels to be quickly connected. While shown as using the lower couplings 142, other couplings such as a bolt can be used to couple the bottom support frame to the floor assembly. In these embodiments, a predetermined hole can be formed in the side panels along with a hole for a bolt to couple the side panel to the floor assembly. In some aspects, and threaded bolt connection can be coupled to the floor assembly when delivered, and the side panels can include a hole that can be placed over the threaded connection to allow a top connector (e.g., a nut and washer) to couple the side panel to the floor assembly in the predetermined locations.

[0053] In some aspects, a weather stripping 143 can be coupled to a lower edge of the support frame 122. The weather stripping can serve to direct any water or moisture outwards from the edge of the support frame, thereby keeping the materials of the support frame 122 dry when exposed to the weather. The w eather stripping 143 can comprise an upper portion coupled to thesupport frame 122 and a lower portion that extends outwards from the support frame 122 to serve as a drip edge. The weather stripping 143 can be formed from any suitable materials such as metal (e.g., galvanized steel, etc.), plastic, concrete board, or the like. The weather stripping 143 can be coupled to the lower portion of the support frame using any suitable couplings such as nails, screws, or the like, and in some aspects, a sealant may be used between the weather stripping 143 and the support frame 122.

[0054] The interior covering 124 may comprise a material such as a laminate, pre-constructed shiplap, sheet rock, or other materials; however, in other embodiments, the configuration of covering 124 may vary. For example, covering 124 may comprise plywood in other embodiments. Additionally, a sealant and / or a decorative material may be applied to covering 124. Covering 124 may provide cover to the support frame 122 on an interior surface of the enclosed structure.

[0055] The exterior covering 126 may comprise a material such as a laminate, pre-constructed shiplap, plywood, concrete board, siding, or the like. In some aspects, the exterior covering 126 may comprise plywood to provide structural support to the side panel 120 while also allowing an additional exterior covering to be coupled to the exterior covering 126. Covering 126 may provide cover to the support frame 122 on an exterior surface of the enclosed structure. When installed, the weather stripping 143 can be positioned between the support frame 122 and the covering 126, or on an exterior of the covering 126. In some aspects, the weather stripping 143 is positioned between the support frame 122 and the covering 126. As shown in FIG. 7, an upper portion of the support frame 122 can be left exposed by the covering 126. This can allow the roof joists to be coupled to the support frame 122 during installation.

[0056] Additionally, an additional siding material 128 (e.g., as shown in FIG. 8) may be applied to exterior covering 126. The siding material 128 can comprise a weather proofing material such as plastic or wooden siding, laminate, concrete based siding, shiplap, metal siding, or the like. In some aspects, an exterior vapor barrier can be installed betw een the exterior covering 126 and the siding material 128. The siding material 128 can be positioned on an exterior surface of the cover 126, and the w eather stripping can be positioned between the siding material 128 and the support frame 122. This positioning can direct any water down the drip edge rather than allowing any water to contact the cover 126 or the support frame 122. The lower couplings 142 can also be left exposed in the side panels 120 to allow the lower couplings 142 to be coupled to the floor assembly during installation.

[0057] An insulating layer can then be formed or placed into the support frame 122 to insulate the side panel 120. The insulation 120 can be positioned within the support frame 122 and may extend between the covering 124 and the exterior covering 126. The insulation can be formedfrom roll insulation (e.g., fiberglass, natural fibers, foam sheeting, etc.), spray insulation (e.g., foam, etc.), or combinations thereof. The insulation can be placed around the various supports when installed.

[0058] The size (e.g., the external dimensions) of the side panels 120 can generally be the same for each of the different types of panels. In some aspects, the side panels 120 may have a smaller dimension (e.g., a width) of at least about 2 feet, at least about 4 feet, at least about 6 feet, at least about 8 feet, at least about 10 feet, or at least about 12 feet. The smaller dimension may be less than about 25 feet, less than about 20 feet, less than about 18 feet, less than about 16 feet, less than about 14 feet, less than about 12 feet, less than about 10 feet, less than about 8 feet, or about 6 feet. In some aspects, the side panels 120 may have a larger dimension (e.g., a length) of at least about 4 feet, at least about 6 feet, at least about 8 feet, at least about 10 feet, at least about 12 feet, or at least about 15 feet. The larger dimension may be less than about 50 feet, less than about 40 feet, less than about 35 feet, less than about 30 feet, less than about 25 feet, less than about 20 feet, less than about 15 feet, or about 12 feet. As an example, the side panels 120 can have an approximate size of 6 feet by 8 feet, and the floor assembly 102 may have a size of 6 feet by 12 feet, where the 6 foot dimension of the side panels 120 can align with the 6 foot dimension of the floor assembly 102.

[0059] In some aspects, the side panels can have a width approximately equal to a smaller dimension of the floor assembly 102, and the floor assembly 102 may have a width to length ratio of between about 0.5: 1 to about 3: 1. or about 1:2. In some aspects, the side panels can have a width approximately equal to a smaller dimension of the floor assembly 102, and the ratio of the width of the side panels can have a ratio of the width to the greater dimension of the floor assembly 102 of betw een about 4:1 to about 1:1, between about 3: 1 to about 1.2: 1, between about 2.5: 1 to about 1.5:1, or about 2: 1. In some aspects, the ratio of the width of the side panels to the greater dimension of the floor assembly 102 can be a whole integer number (e.g., 1 :1, 1:2, etc.). This can allow- the edges of the side panels 120 to align with the foundation supports and / or couplings between adjacent floor assemblies 102 so that a variety of sizes and shapes of enclosed structures can be formed using a limited number of panels.

[0060] In some embodiments, the side panels 120 can be prepared for shipping as shown in FIG. 6. For example, a plurality of side panels 120 can be prepared as part of a kit comprising the support frame 122, the covering 124, the w eather stripping 143, the top couplings 141, and the lower couplings 142. The kit can comprise one or more door panels 120A, one or more window panels 120B, and one or more wall panels 120C. The addition of insulation, exterior covering 126, and siding 128 can be performed at a construction location.

[0061] Referring to FIGS. 9-14, the roof assembly 200 of enclosed structure 100 may generally include a plurality of trusses 202, a plurality of end supports 204, and optionally one or more transition trusses 206. The end supports can be formed from a double truss structure to serve as a structural element with siding. The optional transition trusses can be used for enclosed structures having side extensions as described herein. The plurality of trusses 202, plurality of end supports 204. and the optional one or more transition trusses 206 can be formed from any suitable materials such as wood, steel, or the like. In some aspects, the roof assembly can be formed from wooden boards or beams.

[0062] In some aspects, the plurality of trusses 202 can be formed into a roof assembly 200 at a construction location. The roof assembly 200 can sen e to support the roof of the enclosed structure and transfer the load or weight of the roof onto the outer walls of the enclosed structure 100. The roof assembly can extend entirely across the outer walls of the enclosed structure and can comprise an overhang over the outer panels 120 of the enclosed structure. The plurality' of trusses 202, 204, 206 can be shipped as part of an enclosed structure kit. As shipped, the trusses can be packaged to form a compact structure that can be used at a construction site to form the roof assembly 200. In some aspects, the roof panels 210, 211. 212 can be constructed prior to shipping and shipped as part of the kit. The roof panels 210, 211, 212 can include the trusses, decking, and insulation when shipped as part of the kit.

[0063] The roof assembly 200 can comprise the trusses 202, 204 formed into roof panels 210, 211, 212. The roof panels can be formed into a plurality of panel types to allow for the roof to be installed. An end roof panel 210 can be formed from a plurality of trusses 202 and an end support 204. For example, the end roof panel 210 can be formed from four trusses 202 and one end support 204. The end roof panel 210 can be configured to cover one wall panel and / or floor assembly along with an end overhang for an edge of the enclosed structure 100. The end roof panel 210 can be assembled using the trusses 202 and end support 204 along with a plurality of cross supports and bracing. The cross support 214 can extend along and be coupled to a lower portion of the trusses 202 and end support 204, and a second cross support 215 can extend along and be coupled to an upper portion of the trusses 202 an end support 204 to maintain spacing between the adjacent trusses and end support 204. One or more cross supports can be positioned within the roof assembly 200 to provide cross-bracing for the end roof panel 210. Once placed on the outer panels of the enclosed structure, the end support may extend over the outer panels to provide an overhang on a side or end of the enclosed structure. In some aspects, a plurality of an end roof panels 210 can be used on an enclosed structure with the end roof panels 210 providing the overhang on each end of the enclosed structure.

[0064] Similarly, a center roof panel 211 can be formed from a plurality of trusses 202. For example, the center roof panel 211 can be formed from four trusses 202. The center roof panel 211 can be configured to cover one wall panel and / or floor assembly of the enclosed structure 100. The center roof panel 211 can be assembled using the trusses 202 along with a plurality of cross supports and bracing. The cross support 214 can extend along and be coupled to a lower portion of the trusses 202 and end support 204, and a second cross support 215 can extend along and be coupled to an upper portion of the trusses 202 an end support 204 to maintain spacing between the adjacent trusses and end support 204. One or more cross supports can be positioned within the roof assembly 200 to provide cross-bracing for the center roof panel 211. One or more center roof panels 211 can be used to cover a portion of the enclosed structure between two end roof panels 210 or an end roof panel 210 and a support panel 212.

[0065] A support roof panel 212 can be formed from a plurality of trusses 202 and an end support 204. For example, the support roof panel 212 can be formed from three trusses 202 and one end support 204. The support roof panel 212 can be configured to cover one wall panel and / or floor assembly along without an end overhang. This can be used when the enclosed structure has a turn extending perpendicular to the portion of the enclosed structure on which the support roof panel 212 is placed. Another set of roof panels can be used over the turned portion and placed perpendicular to the support roof panel 212 to form the entire roof structure. In this configuration, the roof panels that are turned perpendicular to the support roof panel 212 can be coupled to and supported by the end support 204 on the support roof panel 212.

[0066] When a support roof panel 212 is present, a transition roof panel 213 can be assembled using a set of progressively smaller trusses 206 along with one or more cross supports. The cross support 216 can extend along and be coupled to a lower or upper portion of the trusses 206 to maintain spacing between the adjacent trusses and end support 204. The transition roof panel 213 may be placed on an end roof panel 210, a center roof panel 21 1, and / or support roof panel 212 to match a roofline of an enclosed structure having a turn or perpendicular section. The transition roof panel 213 can allow for a variety of shapes of enclosed structures to be formed while maintaining the roof panels being positioned and supported by the outer panels of the enclosed structure.

[0067] Each roof panel of the roof assembly 200 can have one or more roof couplings 217 attached to each truss 202 and each end support 204 to mechanically couple the roof panels to the enclosed structure. Referring to FIGS. 8 and 10, the couplings 217 can be formed from any suitable materials, and in some embodiments, the couplings 217 can be formed from metal strips or straps that can be coupled in a plurality of locations (e.g., on each end and / or in the middle) to the truss202 or each end support 204 using mechanical couplings such as screws or nails. In some aspects, the couplings 217 can be the same or similar to the couplings 141. 142 used with the side panels. Once placed on the side panels, the couplings 217 can be coupled to the upper exposed portion 218 of the support frame 122, which can remain exposed during completion to allow the couplings 217 to be attached. The couplings can be attached to the exposed portion 218 using one or more mechanical couplings such as screws, nails, bolts, or the like. Once coupled, the roof panels can be fully coupled through the side panels to the floor assembly through the couplings 141, 142. 217, which can allow the enclosed structure to resist lifting, turning, or shear forces. This can provide a high w ind loading rating to the enclosed structure.

[0068] As noted above, the roof assembly can be shipped as a set of trusses needed to form the roof panels for the enclosed structure being built. In some aspects, the roof panels can be constructed to include the trusses, cross supports, decking and insulation prior to shipping. Once the roof panels are built and the couplings attached, a ceiling covering 220 can be installed on a lower surface of the roof panels. The ceiling covering 220 can comprise a material such as a laminate, pre-constructed shiplap, sheet rock, or other materials. For example, the ceiling covering 220 may comprise sheetrock or the same material as the interior covering on the side panels. The ceiling covering 220 may be installed prior to placing the roof panels on the side panels.

[0069] In some aspects, the roof panels can have a size to cover the length (e.g., the longer dimension) of the floor assembly while also having an additional length to allow for an overhang over the outer walls. In some aspects, the roof panels may have a larger dimension (e.g.. a length) of at least about 12 feet, at least about 14 feet, at least about 16 feet, at least about 18 feet, at least about 20 feet, or at least about 25 feet. The larger dimension may be less than about 55 feet, less than about 50 feet, less than about 45 feet, less than about 40 feet, less than about 35 feet, less than about 30 feet, less than about 25 feet, less than about 20 feet, or about 16 feet.

[0070] As shown in FIG. 11, the ceiling covering 220 may be sized to allow the ceiling covering to be positioned betw een the roof panels and the side panels. This can allows the ceiling covering to directly contacting the interior covering on the side panels to form a finished interior wall and ceiling covering that can be further finished using trim pieces. The portion 221 of the roof panels covering the outside of the side panels can be left open during installation. This can allow' the couplings 217 to be inspected prior to enclosing the roof panels to form an attic space. The roof panels can then be disposed on the side panels to form the roof assembly. Adjacent roof panels can be coupled together using any suitable coupling mechanisms such as screw s, nails, or bolts. This can result in a double truss at the location at which the adjacent roof panels are coupled, which can improve the structural integrity of the resulting enclosed structure.

[0071] As shown in FIG. 12, the portion 221 of the roof that is left open during installation of the roof panels on the side panels can be enclosed with a soffit material 223 once the connections are inspected. The soffit material 223 can be installed using an exterior weather proof material since it is exposed to an exterior of the enclosed structure. Various materials such as siding, wood, concrete siding, or the like can be used for the soffit material 223, and the soffit material 223 can be solid or perforated for air flow. In addition to the soffit material 223, the end roof panel 210 can have an exterior siding 224 installed to enclose the sides of the roof assembly. The siding 224 can comprise any of the exterior materials disclosed herein such as a plastic, metal, or concrete based siding, shiplap, or the like.

[0072] Once the soffit 223 and siding 224 are installed, an insulation 225 can be disposed in the roof assembly to insulate the enclosed structure interior as shown in FIG. 13. The insulation 225 can be positioned within the trusses, and the insulation can be formed from roll insulation (e.g., fiberglass, natural fibers, foam sheeting, etc.), spray insulation (e.g., foam, etc.), or combinations thereof. The insulation 225 may not cover all or a portion of the soffit material, for example, to allow air flow through the attic space in the roof assembly. Each of the roof panels can be insulated with the exception of the transition roof panel as the underlying roof panel under the transition roof panel would be insulated.

[0073] Once the insulation is placed in the roof assembly, decking 226 can be applied to an upper surface of the roof panels. The decking can comprise any suitable decking materials such as pressboard, chip board, plywood, planks, or the like. As shown in FIG. 14, ridge boards 227 can be part of the roof decking. The ridge boards 227 may be left off of the roof assembly and / or removed from the roof assembly to allow inspection of the attic space during the construction process. Once the structure has passed any inspections, the ridge boards 227 can be placed on the structure to form a continuous decking for the placement of roofing materials, which an comprise any suitable roofing materials such as underlayment, shingles, panel roofing (e.g., a metal roof, etc.), or placement of a water proof material directly on the decking. In some aspects, the individual roof panels can be constructed and shipped with the decking and insulation as part of a kit.

[0074] Within the enclosed structure, interior wall panels can also be used (e.g., as shown in FIG. 18). The interior panels can be the same as or similar to the side panels, with the exception that the interior panels may only comprise a support frame and interior and exterior coverings formed from materials such as sheet rock or plywood. In some aspects, the interior walls may not comprise any electrical or plumbing chases, conduits, or pipes. The interior panels can be sized to allow' for doors, closets, or plan w alls. As described above, the roof assembly may be entirelysupported on the side panels, and as a result, the interior panels may only be connected to the floor and side panels, and the interior panels are not load bearing. In some aspects, the interior walls may be coupled to the roof assembly, but in other embodiments, the interior walls may only be coupled to the floor and side panels. When shipped, the interior panels may comprise an internal support frame and external coverings to allow the interior wall panels to be quickly installed.

[0075] As described above, the component construction techniques described herein can allow for enclosed structures to be quickly and easily constructed using a small number of standardized components such as foundation components, the floor assemblies, the side panels, the trusses for the roof, and interior wall panels. These components can be shipped as a kit to the construction location. In some aspects, the component construction kit can comprise additional components such as insulation for the side panels and roof assembly, exterior coverings and siding for the side panels, and / or roofing materials such as decking, shingles, metal roofing, or the like.

[0076] A variety of building designs and dimensions can be created using the component pieces. Using the component construction techniques, the resulting building can generally have dimensions that are a whole number ratio of the widths of the side panels. In some aspects, a building generally having a first lateral dimension (e.g., a length m), and a second later dimension (e.g., a width n), can have an overall size ratio of m:n, where m:n is a whole number ratio. For example, if the width m is taken as the larger dimension, then the ratio m:n can be a w hole number having a value between 1 to 50, or between about 1 to about 20. For example, the ratio m:n can be 1, 2. 3, 4, 5, 6. 7, 8, 9, or 10. though in other embodiments the ratio can be 11 or higher. When side extensions of rooms are included in a non-rectangular design, the side extensions can also have a whole number ratio based on the use of the components.

[0077] Once delivered to the construction site, the enclosed structure can be built from the component construction kit. As shown in FIG. 15, the first step in the construction of an enclosed structure can be installing the foundation. The foundation can comprise any suitable structure, and in some aspects, the foundation 103 can comprise a permanent foundation and / or can form a structural foundation. FIG. 15 illustrates the use of a ground support (e.g., a ground screw) that can be placed into the ground and leveled to form a permanent foundation. The supports can be positioned to align with the floor assembly. As shown in FIG. 18, the supports used to form the foundation can be arranged in a U-shaped building aligning with the edges and comers of the floor assembly. While shown as a U-shaped building to demonstrate one configuration of the enclosed structures, any other shape that can be created with the components can also be used, including several examples described in more details herein. While shown as supports comprising ground screw s, any other suitable foundations can also be used including any of those described herein.

[0078] Once the foundation is installed, the floor assembly can be completed and installed. FIG. 16 shows the floor assembly 102 coupled to the foundation supports 130. As described herein, the floor assembly can be shipped with the support frame and / or electrical components preinstalled. In some aspects, the floor assembly can also include the bottom sheathing and insulation when shipped. Once at the construction location, the support frames can be coupled together and coupled to the foundation supports 130. When installing the floor assemblies to the permanent foundation (e.g., piers, etc.) the bottom sheathing can be opened up to allow for access into the interior of the floor assemblies to install the connections. A sealant such as a ’‘metal tape” could be used to reseal any openings created upon connection of the floor assemblies to the foundation. In some aspects, the access panels 118 may be left off of the floor assembly during installation to allow the support frames to be coupled together and the electrical components to be inspected. Once the support frames are fully coupled and the electrical components have been inspected, the access panels 118 can be reinstalled to complete the flooring. One or more electrical outlets can be present in the flooring to provide power outlets within the enclosed structure. In some embodiments, the outlets may be present on the floor rather than in the walls (e.g., the side panels or interior wall panels).

[0079] Once the floor assembly 102 is complete, the side panels can be installed to form the outer walls of the enclosed structure. As described in more detail herein, the side panels 120 can comprise a support frame, an interior covering, couplings, and weather stripping when shipped as part of a component construction kit. Once delivered to the construction site, the side panels can be placed on the floor assembly to form the walls. Each side panel can be placed on the floor assembly with the lower coupling extending below the edge of the support frames to align with an outer edge of the floor assembly. The lower couplings can be coupled to the side panels, and once placed on the floor assembly, can be further coupled to the floor assembly using any suitable mechanical couplings. For example, the lower couplings can be screwed into the support frame or floor on the floor assembly. This can provide a tie down point for the side panels to prevent any uplift or shear forces from moving the side panels. In some aspects, the support frames of the side panels can be further coupled to the flooring using connectors such as screws or nails.

[0080] Once the first side panel has been installed, the next side panel can be placed adjacent the first side panel and installed. Adjacent side panels can be coupled by attaching the adjacent edges of the side panels together with screws or nails. This connection point can result in a double stud being formed at the connection point. Based on the standard sizing of the side panels and floor assembly, the double stud can be posited over the foundation support to allow weight from the roof assembly or a second floor to be transmitted to the foundation through the double stud atthe connection between adjacent side panels. The side panels can continue to be installed around the perimeter of the floor assembly to form the final outer wall of the enclosed structure. The selection of the side panels can be used to form the desired placement of windows and doors into the enclosed structure. During the installation process, the lower couplings (e.g., as shown in FIG. 6) can be coupled to the floor assembly to mechanically tie the side panels to the floor assembly.

[0081] As shown in FIG. 17, a seam 250 can be formed between the interior coverings on adjacent side panels 120. which can be in addition to one or more seams formed between pieces of interior coverings used to form the side panels. The seams can remain visible after installation, or in some embodiments, a finish stripping or taping and bedding can be used to provide a finished look to the seams. The seams may not be structural, and they can be left without affecting the integrity of the enclosed structure. In some aspects, other wall coverings such as wallpaper, shiplap, or the like can be used to cover the seams on the outer w alls.

[0082] Once the side panels are installed, the lower couplings can be inspected and the insulation and exterior coverings can be installed on each side panel. The exterior coverings can comprise plywood in some aspects to provide structural support to the side panels. The siding material can then be installed over the exterior covering to form the outer walls. As descnbed herein, an upper portion of the support frame can remain exposed on the side panels to allow the roof to be installed.

[0083] Once the side panels are completed to form the outer w alls, the interior walls 401 can be installed, as shown in FIG. 18. The interior walls can comprise panels having a support frame and coverings on one or both sides when delivered. In some aspects, only one side of the wall panels may have a covering to allow' the wall panel 401 to be coupled to the side panels, floor, and / or roof assembly. The interior w alls can be arranged and installed to form rooms within the enclosed structure. The interior wall panels may be provided and installed without doors or hardware, and the additional components can be installed after the interior walls are installed.

[0084] In some aspects, the walls, including the outer walls and the interior walls, can be secured using an optional top plate 407 formed on the top of all of the walls. The top plate can comprise a wooden or metal structure coupled to a top of all of the walls to interlock the walls together. This can support the walls during the installation of the roof while also providing structural stability once completed.

[0085] In order to provide utilities into the enclosed structure, a mechanical chase 403 can be formed using two interior w all panels 402. As shown in FIG. 18, the two interior wall panels 402 may only be finished on one side each with the unfinished sides forming a mechanical chase 403. The mechanical chase 403 can lead from a side panel to a center of the enclosed structure, and canprovide space to run plumbing, electrical, venting, and / or air conditioning and heating lines (e.g., coolant lines for a heat pump, air conditioning, etc.). The mechanical chase 403 can allow for a bathroom and kitchen to be installed on either side of the mechanical chase with the appropriate plumbing in the mechanical chase and extending through the interior panels 402 of the mechanical chase. The mechanical chase 403 may be accessible through a side panel on the exterior wall and / or through the floor assembly. While only one mechanical chase 403 is shown in FIG. 18, two or more mechanical chases can be used for larger structures to allow for multiple water and mechanical connection points within the enclosed structure.

[0086] Once the exterior and interior walls are installed, the roof assembly 200 can be installed. As shown in FIG. 19, the roof assembly can be placed upon and coupled to the exterior wall to form the roof. In some aspects, the trusses can be delivered and constructed into one of the four types of roof panels as described herein, where the roof panels can be constructed from the trusses shipped in the kit for the component construction. Once constructed, the roof panels can have the ceiling material installed and placed on the side panels. The couplings from the trusses to the exposed portion of the side panels can be coupled to tie down the roof. Once inspected, the roof can be enclosed with end panels and soffit materials before installing insulation and roof decking. In some aspects, the individual roof panels can be constructed prior to shipping and shipped as part of the kit. The individual roof panels can comprise the decking and insulation.

[0087] As shown in FIG. 19. the types of roof panels can be selected based on the shape and configuration of the enclosed structure. The end roof panels 210 can be used in each location over an end of the enclosed structure. The center roof panels 21 1 can be used between two end roof panels 210 and / or between an end roof panel 210 and a support roof panel 212. The building extensions are shown with support roof panels 212 next to the end roof panel 210. The support roof panels 212 can be placed on the side panels with the trusses aligned perpendicular to the trusses in the adjacent end roof panel 210 and center roof panels 211 on the main structure. The ends of the adj acent end roof panel 210 and center roof panels 211 can be coupled to and supported by the support roof panel 212 so that the weight of the roof is not placed on any interior walls. A transition roof panel 213 can then be placed between the support roof panel 212 and the perpendicular end roof panel 210 and center roof panels 211 to allow the roofline to tie into the roofline of the main structure. The roof can then be supported entirely on the outer wall formed by the side panels, w here the transition roof panel is supported by the support roof panel 212 and the perpendicular roof panels without transferring any w eight on the interior w alls. Roofing materials can then be installed to form a completed enclosed structure as shown in FIG. 20.

[0088] During the construction process, the lower couplings (e.g., as shown in FIG. 6) can be coupled to the floor assembly, and once the roof is positioned on the walls, one or more roof couplings can be used to mechanically couple the walls (e.g., the side panels forming the outer wall and / or the interior walls) to the roof. The roof couplings can be the same or similar to the lower couplings and the upper couplings, and may in some aspects be angled to allow the walls to be coupled to a roof truss placed perpendicular to the wall panel. In some aspects, the upper coupling can be coupled directly to the roof panels, or the roof couplings can be directly coupled to an upper portion of the walls. The resulting assembly can then allow for a mechanical connection from the roof, through the wall panels, through the floor assembly, to the foundation to tie down the structure, thereby allowing for a relatively large wind load rating for the structure.

[0089] In some embodiments, the enclosed structures can be deconstructed using the reverse process as described herein. Since the components are generally assembled using connectors such as screws, the components can be deconstructed to obtain the individual components, which can be reused for one or more enclosed structures. For example, the foundation, floor assemblies, side panels, interior walls, and / or roof panels or trusses can be disassembled and stored for use in future enclosed structures. This can allow for the components to be used on the same or on different configurations of enclosed structures.

[0090] While FIGS. 15-20 illustrate the construction of a U-shaped enclosed structure, any configuration that can be built from the components as described herein can be constructed using the component construction kits and processes as described herein. An example of a different enclosed structure is shown in FIG. 21 as an example. As illustrates, the layout of the enclosed structure 500 can be configured as a rectangle, and the remaining components can be the same including a foundation with support structure 103, side panels 120, an interior floor assembly, and a roof 502. The components of the structure 500 can be the same as those described herein with the exception that the roof assembly 502 may comprise a single pitch roof. The rafters in the roof assembly 502 can be slanted to provide a slope for the roof, which an be finished with shingles or a metal roofing as described herein. The final structure 500 with the roof assembly completed is shown in FIG. 22. The low-slope roof may provide a cost savings relatively a standard roof, and can be completed as a panel that can be shipped with the other components of the kit.

[0091] The components as disclosed herein can also be used to form a multi-story enclosed structure as shown in FIG. 23. As illustrates, the enclosed structure 600 can be constructed as described herein with respect to the foundation and support structures 103, the floor assembly, and the side panels. Prior to placing the roof panels on the enclosed structure 600, a second floor assembly 602 can be placed on the top of the first floor side panels 120. The second floor assembly602 can be similar to the floor assembly used for the first floor and described herein. In these embodiments, the exposed top portion of the side panels can be used to providing a coupling between the second floor assembly 602 and the top of the first floor side panels. The second floor assembly 602 may have a lower covering that may not be weather proof since it is exposed to an interior of the enclosed structure 600. The electrical components may still be present in the second floor assembly 602 to allow power to be provided in the second story’.

[0092] Once the second floor assembly 602 is installed, a second set of side panels 620 can be installed on the second floor assembly 602. The side panels can be installed in the same way as the side panels 120 used for the first floor. The configuration of the doors, windows, and solid panels can be the same or different between the two floors. Further, the interior walls can be arranged in the same or in a different way as the first floor, as shown in FIG. 24. Since the interior walls are not load bearing, the configuration of the interior can be modified between the floors. Once the interior walls (if any) are completed, the roof assembly can be installed as described herein. Since the door panel may be an exterior door on the second story, an exterior staircase can be constructed to reach the second story.

[0093] As descnbed herein, the adjacent wall panels in the exterior wall can result in a double stud being formed over the connection between adjacent support frames in the floor and the foundation supports. This configuration can result in support points aligned up through the first floor, through the second floor assembly, the second floor side panels, and the roof assembly to provide structural support to the entire enclosed structure.

[0094] As a further example of enclosed structures, FIG. 25 illustrates a simple structure formed from the components described herein. As shown the enclosed structure can comprise a floor assembly comprising one or two support frames, a corresponding number of side panels, and pair of end roof panels to form the entire structure. FIG. 25 represents a simple enclosed structure to illustrates that any number of component pieces can be arranged and assembled to form simple to complex structures.

[0095] Having described various kits, structures, assemblies, and methods, certain aspects can include, but are not limited to:

[0096] In a first aspect, a kit for constructing an enclosed structure comprises a plurality of support frames for a floor assembly; a plurality of side panels, wherein the side panels each comprise a side panel support frame, and an interior covering coupled to the side panel support frame; and a plurality of roof trusses.

[0097] A second aspect can include the kit of the first aspect, further comprising: flooring panels, wherein the flooring panels are sized to be coupled to each support frame of the plurality of support frames for the floor assembly.

[0098] A third aspect can include the kit of the first or second aspect, further comprising: wherein the plurality of support frames for the floor assembly are formed from metal.

[0099] A fourth aspect can include the kit of any one of the first to third aspects, further comprising: wherein the plurality of support frames comprise electrical conduits.

[0100] A fifth aspect can include the kit of any one of the first to fourth aspects, wherein the plurality of side panels comprise: at least one side panel of the plurality of side panels comprising a door; at least one side panel of the plurality of side panels comprising a window; and at least one side panel of the plurality of side panels comprising a solid side panel.

[0101] A sixth aspect can include the kit of any one of the first to fifth aspects, wherein the plurality of side panels have a width matching at least one of a length or width of the plurality of support frames for the floor assembly.

[0102] A seventh aspect can include the kit of any one of the first to sixth aspects, wherein the plurality of side panels comprise upper couplings coupled to an upper portion of each side panel of the plurality of side panels, and lower couplings coupled to a lower portion of each side panel of the plurality of side panels.

[0103] An eighth aspect can include the kit of any one of the first to seventh aspects, further comprising: a plurality of exterior covering sheets, wherein the plurality of exterior covering sheets are sized to be coupled to one or more side panels of the plurality of side panels.

[0104] A ninth aspect can include the kit of any one of the first to eighth aspects, further comprising: a plurality of siding sheets, wherein the plurality of siding sheets are sized to be coupled to one or more side panels of the plurality of side panels.

[0105] A tenth aspect can include the kit of any one of the first to ninth aspects, further comprising: a plurality of foundation supports.

[0106] An eleventh aspect can include the kit of any one of the first to tenth aspects, further comprising: a plurality of interior wall panels.

[0107] In a twelfth aspect, an enclosed structure comprises: a floor assembly comprising a plurality of support frames coupled together and a floor placeable upon the plurality of support frames; a plurality of side panels, wherein each side panel of the plurality of side panels is coupled to an adjacent side panel to form an exterior wall; and a roof assembly disposed on and coupled to the plurality of side panels.

[0108] A thirteenth aspect can include the enclosed structure of the twelfth aspect, wherein the plurality of support frames of the floor assembly is formed from metal.

[0109] A fourteenth aspect can include the enclosed structure of the twelfth or thirteenth aspect, further comprising: a foundation, wherein the floor assembly is disposed on and coupled to the foundation.

[0110] A fifteenth aspect can include the enclosed structure of any one of the twelfth to fourteenth aspects, wherein a double stud is formed at a coupling point between adjacent side panels of the plurality of side panels.

[0111] A sixteenth aspect can include the enclosed structure of any one of the twelfth to fifteenth aspects, wherein the plurality of side panels are mechanically coupled to the floor assembly.

[0112] A seventeenth aspect can include the enclosed structure of any one of the twelfth to sixteenth aspects, wherein one or more coupling points between adjacent side panels of the plurality of side panels is aligned with one or more coupling points of the support frames of the floor assembly.

[0113] An eighteenth aspect can include the enclosed structure of any one of the twelfth to seventeenth aspects, wherein the roof assembly is mechanically coupled to the plurality of side panels.

[0114] In a nineteenth aspect, a method of constructing an enclosed structure comprises: coupling a plurality of support frames together to form a floor assembly; disposing a floor to the plurality of support frames; coupling a plurality of side panels together on top of the floor, wherein each side panel of the plurality of side panels is coupled to an adjacent side panel to form an exterior wall; coupling the plurality of side panels to the floor assembly; and disposing a roof assembly on the exterior wall and coupling the roof to the plurality of side panels.

[0115] A twentieth aspect can include the method of the nineteenth aspect, wherein the plurality of support frames of the floor assembly are formed from metal.

[0116] A twenty first aspect can include the method of the nineteenth or twentieth aspect, further comprising: disposing a floor assembly on and coupling the floor assembly to the foundation.

[0117] A twenty second aspect can include the method of any one of the nineteenth to twenty first aspects, wherein a double stud is formed at a coupling point between adjacent side panels of the plurality of side panels.

[0118] A twenty third aspect can include the method of any one of the nineteenth to twenty second aspects, wherein the plurality of side panels are mechanically coupled to the floor assembly.

[0119] A twenty fourth aspect can include the method of any one of the nineteenth to twenty third aspects, wherein one or more coupling points between adjacent side panels of the plurality’ of side panels is aligned with one or more coupling points of the support frames of the floor assembly.

[0120] A twenty fifth aspect can include the method of any one of the nineteenth to twenty fourth aspects, wherein the roof assembly is mechanically coupled to the plurality7of side panels.

[0121] While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many7other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.

[0122] Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims

CLAIMSWhat is claimed is:

1. A method for manufacturing component construction, the method comprising: producing a plurality of side panels for a structure, wherein the plurality of side panels is produced to be a predetermined size, and wherein the predetermined size is compatible to fit a floor assembly; and constructing at least one coupling point for each side panel of the plurality of side panels, wherein the at least one coupling point couples to predetermined location of the floor assembly, and wherein the at least one coupling point for each side panel is constructed to couple the at least one coupling point of each side panel to the floor assembly at the location of the construction.

2. The method of claim 1, wherein the plurality of side panels comprises: at least one side panel of the plurality of side panels comprising a door; at least one side panel of the plurality of side panels comprising a window; and at least one side panel of the plurality of side panels comprising a solid side panel.

3. The method of claim 1, wherein the plurality of side panels have a width matching at least one of a length or width of a support frame of the floor assembly.

4. The method of claim 1, wherein the plurality of side panels comprise upper couplings coupled to an upper portion of each side panel of the plurality of side panels, and wherein the at least one coupling point comprises lower couplings coupled to a lower portion of each side panel of the plurality of side panels.

5. The method of claim 1, further comprising: a plurality of exterior covering sheets, wherein the plurality of exterior covering sheets are sized to be coupled to one or more side panels of the plurality of side panels.

6. The method of claim 1, further comprising: a plurality of siding sheets, wherein the plurality of siding sheets are sized to be coupled to one or more side panels of the plurality of side panels.

7. The method of claim 1, wherein the flooring panels are sized to be coupled to a support frame of the plurality of support frames for the floor assembly.

8. The method of claim 7, wherein the plurality of support frames for the floor assembly are formed from metal.

9. The method of claim 7, wherein the plurality of support frames comprises electrical conduits.

10. A side panel for construction to form at least one of outside or inside wall, the side panel comprising: a support frame; an external covering coupled to the support frame; at least one coupling point coupled to the support frame; wherein the side panels have a predetermined size, wherein the coupling point is configured to couple to a predetermined location of a floor assembly, wherein the at least one coupling point of the side panels couples to the floor assembly at the location of the construction.

11. The side panel of claim 10, wherein the side panel comprises one of a door panel, a window panel, or a solid side panel.

12. The side panel of claim 10, wherein the side panel has a width matching at least one of a length or width of a support frame of the floor assembly.

13. The side panel of claim 10. wherein the side panel comprises upper couplings coupled to an upper portion of each side panel of the plurality of side panels, and wherein the at least one coupling point comprises lower couplings coupled to a lower portion of each side panel of the plurality of side panels.

14. The side panel of claim 10. further comprising: an exterior covering sheet, wherein the exterior covering sheet is sized to be coupled to side panel.

15. The side panel of claim 10, further comprising: a siding sheet, wherein the siding sheet is sized to be coupled to the side panel.

16. An enclosed structure comprising: a floor assembly comprising a plurality of support frames coupled together and a floor placeable upon the plurality of support frames; a plurality of side panels, wherein each side panel of the plurality of side panels is coupled to an adjacent side panel to form an exterior wall; and a roof assembly disposed on and coupled to the plurality of side panels.

17. The enclosed structure of claim 16, wherein the plurality of support frames of the floor assembly are formed from metal.

18. The enclosed structure of claim 16. further comprising: a foundation, wherein the floor assembly is disposed on and coupled to the foundation.

19. The enclosed structure of claim 16, wherein a double stud is formed at a coupling point between adjacent side panels of the plurality of side panels.

20. The enclosed structure of claim 16, wherein the plurality of side panels are mechanically coupled to the floor assembly.

21. The enclosed structure of claim 16, wherein one or more coupling points betw een adj acent side panels of the plurality’ of side panels is aligned with one or more coupling points of the support frames of the floor assembly.

22. The enclosed structure of claim 16, wherein the roof assembly is mechanically coupled to the plurality' of side panels.

23. The enclosed structure of claim 16, w herein each side panel of the plurality of side panels had a width of n, wherein each support frame of the plurality of support frames has a smaller dimension m, and wherein a ratio of n:m is between 2: 1 to 1 :2.

24. The enclosed structure of claim 16, wherein each side panel of the plurality' of side panels had a width of n, wherein each support frame of the plurality of support frames has a larger dimension m, and yvherein a ratio of n:m is between 4: 1 to 1 : 1.

25. A method of constructing an enclosed structure, the method comprising: coupling a plurality of support frames together to form a floor assembly; disposing a floor to the plurality of support frames; coupling a plurality of side panels together on top of the floor, wherein each side panel of the plurality of side panels is coupled to an adjacent side panel to form an exterior wall; coupling the plurality of side panels to the floor assembly; and disposing a roof assembly on the exterior wall and coupling the roof to the plurality of side panels.

26. The method of claim 25, wherein the plurality of support frames of the floor assembly are formed from metal.

27. The method of claim 25, further comprising: disposing a floor assembly on and coupling the floor assembly to the foundation.

28. The method of claim 25, wherein a double stud is formed at a coupling point between adjacent side panels of the plurality' of side panels.

29. The method of claim 25, wherein the plurality of side panels are mechanically coupled to the floor assembly.

30. The method of claim 25, wherein one or more coupling points between adjacent side panels of the plurality of side panels is aligned with one or more coupling points of the support frames of the floor assembly.

31. The method of claim 25, wherein the roof assembly is mechanically coupled to the plurality of side panels.

32. The method of claim 25, wherein each side panel of the plurality of side panels had a width of n, wherein each support frame of the plurality of support frames has a smaller dimension m, and wherein a ratio of n:m is between 2: 1 to 1 :2.

33. The method of claim 25, wherein each side panel of the plurality of side panels had a width of n, wherein each support frame of the plurality of support frames has a larger dimension m, and wherein a ratio of n:m is between 4: 1 to 1 : 1.

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