U.S. patent application number 10/552100 was filed with the patent office on 2006-10-12 for prefabricated folding structure having interlocking metal beams.
Invention is credited to Vincent Shanni.
Application Number | 20060225371 10/552100 |
Document ID | / |
Family ID | 33097121 |
Filed Date | 2006-10-12 |
United States Patent
Application |
20060225371 |
Kind Code |
A1 |
Shanni; Vincent |
October 12, 2006 |
Prefabricated folding structure having interlocking metal beams
Abstract
The invention provides prefabricated folding residential
dwellings comprised of prefabricated floor, wall and roof members
that fold inwardly upon itself to produce a compact partially
collapsed folded structure, which is easily transportable, and then
unfold outwardly for quick and easy on-site installation.
Inventors: |
Shanni; Vincent; (Scotch
Plains, NJ) |
Correspondence
Address: |
Richard S Roberts;Roberts & Roberts
P.O .Box 484
Princeton
NJ
08542-0484
US
|
Family ID: |
33097121 |
Appl. No.: |
10/552100 |
Filed: |
March 30, 2004 |
PCT Filed: |
March 30, 2004 |
PCT NO: |
PCT/US04/09664 |
371 Date: |
September 30, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10405550 |
Apr 1, 2003 |
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10552100 |
Sep 30, 2005 |
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Current U.S.
Class: |
52/79.5 |
Current CPC
Class: |
E04B 1/3442
20130101 |
Class at
Publication: |
052/079.5 |
International
Class: |
E04H 6/00 20060101
E04H006/00 |
Claims
1. A prefabricated folding structure comprising: a generally
rectangular central core comprising a plurality of core walls, a
core floor section connected to and extending between the core
walls at a base of the core walls, and a core roof section
connected to and over the core walls and over the core floor
section; each of said core walls, core floor section and core roof
section comprising a plurality of spaced metal channel beams having
at least one flat side; a plurality of folding rooms attached to
the central core; each folding room comprising a plurality of room
wall members, a folding room floor section removably attached to
and extending between the room walls at a base of the room walls
and a folding a room roof section removably attached to and
extending over the room wall members and extending over the room
floor section; each of the room wall members, the room floor
section and the room roof section comprising a plurality of spaced
metal channel beams having at least one flat side; at least one
said room floor section being pivotedly connected at one end
thereof to said core floor section; at least said one room roof
section being pivotedly connected at one end thereof to said core
roof section; said room wall members being removably attached to
said room floor section and said room roof section; each room roof
section being pivotedly connected to the core roof section on the
same side of the central core as each room floor section is
connected to the core floor section; wherein each folding room
floor section and each folding room roof section may be alternately
detached from its room wall members and pivoted inwardly toward
said central core and positioned in close proximity to and
substantially parallel to a corresponding core wall and thereby
form a compact folded structure, or pivoted outwardly away from
said central core to define a room adjacent to said central core
when attached to its room wall members.
2. The structure of claim 1 wherein the beams comprise steel.
3. The structure of claim 1 wherein the beams pivot around
bolts.
4. The structure of claim 1 wherein the beams have a generally
U-shaped cross-section with a wide flat side extending to opposite
perpendicular edges.
5. The structure of claim 1 wherein the beams have a generally
C-shaped cross-section with a wide flat side extending to opposite
perpendicular edges having perpendicularly inwardly positioned edge
flanges.
6. The structure of claim 1 wherein adjacent beams are positioned
with their respective wide flat sides in juxtaposition and said
beams being attached together with a plurality of bolts and
nuts.
7. The structure of claim 1 wherein said core walls and said room
wall members further comprise a plurality of spaced metal channel
studs having at least one flat side.
8. The structure of claim 1 wherein said core roof section
comprises a plurality of rafters, said rafters comprising a pair of
metal channel beams having at least one flat side, and which pair
of beams are attached together at one end of each of said beams via
at least one bolt and nut, one of said rafter beams being notched
and the other of said rafter beams being positioned within the
notch such that said rafter beams are interlocking with one
another.
9. The structure of claim 1 wherein said core roof section
comprises a plurality of rafters, said rafters comprising a pair of
metal channel beams having at least one flat side, and which pair
of beams are attached together at one end of each of said beams via
at least one bolt and nut, one of said rafter beams being notched
and the other of said rafter beams being positioned within the
notch such that said rafter beams are interlocking with one
another; and each room roof section being pivotedly connected to
the core roof section via an end of a rafter beam on the same side
of the central core as each room floor section is connected to the
core floor section.
10. The structure of claim 9 wherein the core roof section
comprises a plurality of further comprises a plurality of metal
channel core roof section supports, each one of said core roof
section supports being positioned within a notch in one of the
rafters and attached to said rafter via at least one bolt and nut
such that said supports and said rafter beams are interlocking with
one another.
11. The structure of claim 9 wherein each room roof section
comprises a plurality of metal channel room roof section supports,
each room roof section being pivotedly connected to the core roof
section by pivotally connecting each of the room roof section
supports by a bolt and nut to one of said rafter beams.
12. A multistory prefabricated folding structure comprising: a
generally rectangular central core comprising a plurality of core
walls, a core floor section connected to and extending between the
core walls at a base of the core walls, and a core roof section
connected to and over the core walls and over the core floor
section; each of said core walls, core floor section and core roof
section comprising a plurality of spaced metal channel beams having
at least one flat side; a plurality of folding rooms attached to
the central core; each folding room comprising a plurality of room
wall members, a folding room floor section removably attached to
and extending between the room walls at a base of the room walls
and a folding a room roof section removably attached to and
extending over the room wall members and extending over the room
floor section; each of the room wall members, the room floor
section and the room roof section comprising a plurality of spaced
metal channel beams having at least one flat side; at least one
said room floor section being pivotedly connected at one end
thereof to said core floor section; at least said one room roof
section being pivotedly connected at one end thereof to said core
roof section; said room wall members being removably attached to
said room floor section and said room roof section; each room roof
section being pivotedly connected to the core roof section on the
same side of the central core as each room floor section is
connected to the core floor section; a sub-core attached under the
central core, said sub-core comprising a generally rectangular
central sub-core comprising a plurality of sub-core walls, a
sub-core floor section connected to and extending between the
sub-core walls at a base of the sub-core walls, each of said
sub-core walls and the sub-core floor section comprising a
plurality of spaced metal channel beams having at least one flat
side; a plurality of folding sub-rooms, one folding sub-room
attached under one of the folding rooms and also attached to the
central sub-core; each folding sub-room comprising a plurality of
sub-room wall members, and a folding sub-room floor section
removably attached to and extending between the sub-room walls at a
base of the sub-room walls; each of the sub-room wall members and
the sub-room floor section comprising a plurality of spaced metal
channel beams having at least one flat side; at least one said
sub-room floor section being pivotedly connected at one end thereof
to said sub-core floor section; said sub-room wall members being
removably attached to said sub-room floor section; wherein each
folding room floor section and each folding room roof section may
be alternately detached from its room wall members and pivoted
inwardly toward said central core or central sub-core and
positioned in close proximity to and substantially parallel to a
corresponding core wall or sub-core wall and thereby form a compact
folded structure, or pivoted outwardly away from said central core
to define a room adjacent to said central core when attached to its
room wall members; wherein each folding sub-room floor section may
be alternately detached from its sub-room wall members and pivoted
inwardly toward said central sub-core and positioned in close
proximity to and substantially parallel to a corresponding sub-core
wall and thereby form a compact folded structure, or pivoted
outwardly away from said central sub-core to define a room adjacent
to said central sub-core when attached to its sub-room wall
members.
13. The structure of claim 12 wherein the beams comprise steel.
14. The structure of claim 12 wherein the beams pivot around
bolts.
15. The structure of claim 12 wherein the beams have a generally
U-shaped cross-section with a wide flat side extending to opposite
perpendicular edges.
16. The structure of claim 12 wherein the beams have a generally
C-shaped cross-section with a wide flat side extending to opposite
perpendicular edges having perpendicularly inwardly positioned edge
flanges.
17. The structure of claim 12 wherein adjacent beams are positioned
with their respective wide flat sides in juxtaposition and said
beams being attached together with a plurality of bolts and
nuts.
18. The structure of claim 12 wherein said core walls, room wall
members, sub-core walls and sub-room wall members further comprise
a plurality of spaced metal channel studs having at least one flat
side.
19. The structure of claim 12 wherein said core roof section
comprises a plurality of rafters, said rafters comprising a pair of
metal channel beams having at least one flat side, and which pair
of beams are attached together at one end of each of said beams via
at least one bolt and nut, one of said rafter beams being notched
and the other of said rafter beams being positioned within the
notch such that said rafter beams are interlocking with one
another.
20. The structure of claim 12 wherein said core roof section
comprises a plurality of rafters, said rafters comprising a pair of
metal channel beams having at least one flat side, and which pair
of beams are attached together at one end of each of said beams via
at least one bolt and nut, one of said rafter beams being notched
and the other of said rafter beams being positioned within the
notch such that said rafter beams are interlocking with one
another; and each room roof section being pivotedly connected to
the core roof section via an end of a rafter beam on the same side
of the central core as each room floor section is connected to the
core floor section.
21. The structure of claim 20 wherein the core roof section further
comprises a plurality of metal channel core roof section supports,
each one of said core roof section supports being positioned within
a notch in one of the rafters and attached to said rafter via at
least one bolt and nut such that said supports and said rafter
beams are interlocking with one another.
22. The structure of claim 20 wherein each room roof section
comprises a plurality of metal channel room roof section supports,
each room roof section being pivotedly connected to the core roof
section by pivotally connecting each of the room roof section
supports by a bolt and nut to one of said rafter beams.
23. A three-story prefabricated folding structure comprising: a
generally rectangular central core comprising a plurality of core
walls, a core floor section connected to and extending between the
core walls at a base of the core walls, and a core roof section
connected to and over the core walls and over the core floor
section; each of said core walls, core floor section and core roof
section comprising a plurality of spaced metal channel beams having
at least one flat side; a plurality of folding rooms attached to
the central core; each folding room comprising a plurality of room
wall members, a folding room floor section removably attached to
and extending between the room walls at a base of the room walls
and a folding a room roof section removably attached to and
extending over the room wall members and extending over the room
floor section; each of the room wall members, the room floor
section and the room roof section comprising a plurality of spaced
metal channel beams having at least one flat side; at least one
said room floor section being pivotedly connected at one end
thereof to said core floor section; at least said one room roof
section being pivotedly connected at one end thereof to said core
roof section; said room wall members being removably attached to
said room floor section and said room roof section; each room roof
section being pivotedly connected to the core roof section on the
same side of the central core as each room floor section is
connected to the core floor section; a sub-core attached under the
central core, said sub-core comprising a generally rectangular
central sub-core comprising a plurality of sub-core walls, a
sub-core floor section connected to and extending between the
sub-core walls at a base of the sub-core walls, each of said
sub-core walls and the sub-core floor section comprising a
plurality of spaced metal channel beams having at least one flat
side; a plurality of folding sub-rooms, one folding sub-room
attached under one of the folding rooms and also attached to the
central sub-core; each folding sub-room comprising a plurality of
sub-room wall members, and a folding sub-room floor section
removably attached to and extending between the sub-room walls at a
base of the sub-room walls; each of the sub-room wall members and
the sub-room floor section comprising a plurality of spaced metal
channel beams having at least one flat side; at least one said
sub-room floor section being pivotedly connected at one end thereof
to said sub-core floor section; said sub-room wall members being
removably attached to said sub-room floor section; wherein each
folding room floor section and each folding room roof section may
be alternately detached from its room wall members and pivoted
inwardly toward said central core or central sub-core and
positioned in close proximity to and substantially parallel to a
corresponding core wall or sub-core wall and thereby form a compact
folded structure, or pivoted outwardly away from said central core
to define a room adjacent to said central core when attached to its
room wall members; wherein each folding sub-room floor section may
be alternately detached from its sub-room wall members and pivoted
inwardly toward said central sub-core and positioned in close
proximity to and substantially parallel to a corresponding sub-core
wall and thereby form a compact folded structure, or pivoted
outwardly away from said central sub-core to define a room adjacent
to said central sub-core when attached to its sub-room wall
members; a second sub-core attached under the sub-core, said second
sub-core comprising a generally rectangular central second sub-core
comprising a plurality of second sub-core walls, a second sub-core
floor section connected to and extending between the second
sub-core walls at a base of the second sub-core walls, each of said
second sub-core walls and the second sub-core floor section
comprising a plurality of spaced metal channel beams having at
least one flat side; a plurality of folding second sub-rooms, one
folding second sub-room attached under one of the folding sub-rooms
and also attached to the central second sub-core; each folding
second sub-room comprising a plurality of second sub-room wall
members, and a folding second sub-room floor section removably
attached to and extending between the second sub-room walls at a
base of the second sub-room walls; each of the second sub-room wall
members and the second sub-room floor section comprising a
plurality of spaced metal channel beams having at least one flat
side; at least one said second sub-room floor section being
pivotedly connected at one end thereof to said second sub-core
floor section; said second sub-room wall members being removably
attached to said second sub-room floor section; wherein each
folding room floor section and each folding room roof section may
be alternately detached from its room wall members and pivoted
inwardly toward said central core or central sub-core and
positioned in close proximity to and substantially parallel to a
corresponding core wall or sub-core wall and thereby form a compact
folded structure, or pivoted outwardly away from said central core
to define a room adjacent to said central core when attached to its
room wall members; wherein each folding sub-room floor section may
be alternately detached from its sub-room wall members and pivoted
inwardly toward said central sub-core and positioned in close
proximity to and substantially parallel to a corresponding sub-core
wall and thereby form a compact folded structure, or pivoted
outwardly away from said central sub-core to define a room adjacent
to said central sub-core when attached to its sub-room wall
members; wherein each folding second sub-room floor section may be
alternately detached from its second sub-room wall members and
pivoted inwardly toward said central second sub-core and positioned
in close proximity to and substantially parallel to a corresponding
second sub-core wall and thereby form a compact folded structure,
or pivoted outwardly away from said central second sub-core to
define a room adjacent to said central second sub-core when
attached to its second sub-room wall members.
24. The structure of claim 23 wherein the beams comprise steel.
25. The structure of claim 23 wherein the beams pivot around
bolts.
26. The structure of claim 23 wherein the beams have a generally
U-shaped cross-section with a wide flat side extending to opposite
perpendicular edges.
27. The structure of claim 23 wherein the beams have a generally
C-shaped cross-section with a wide flat side extending to opposite
perpendicular edges having perpendicularly inwardly positioned edge
flanges.
28. The structure of claim 23 wherein adjacent beams are positioned
with their respective wide flat sides in juxtaposition and said
beams being attached together with a plurality of bolts and
nuts.
29. The structure of claim 23 wherein said core walls, room wall
members, sub-core walls, sub-room wall members, second sub-core
walls, and second sub-room wall members further comprise a
plurality of spaced metal channel studs having at least one flat
side.
30. The structure of claim 23 wherein said core roof section
comprises a plurality of rafters, said rafters comprising a pair of
metal channel beams having at least one flat side, and which pair
of beams are attached together at one end of each of said beams via
at least one bolt and nut, one of said rafter beams being notched
and the other of said rafter beams being positioned within the
notch such that said rafter beams are interlocking with one
another.
31. The structure of claim 23 wherein said core roof section
comprises a plurality of rafters, said rafters comprising a pair of
metal channel beams having at least one flat side, and which pair
of beams are attached together at one end of each of said beams via
at least one bolt and nut, one of said rafter beams being notched
and the other of said rafter beams being positioned within the
notch such that said rafter beams are interlocking with one
another; and each room roof section being pivotedly connected to
the core roof section via an end of a rafter beam on the same side
of the central core as each room floor section is connected to the
core floor section.
32. The structure of claim 31 wherein the core roof section further
comprises a plurality of metal channel core roof section supports,
each one of said core roof section supports being positioned within
a notch in one of the rafters and attached to said rafter via at
least one bolt and nut such that said supports and said rafter
beams are interlocking with one another.
33. The structure of claim 31 wherein each room roof section
comprises a plurality of metal channel room roof section supports,
each room roof section being pivotedly connected to the core roof
section by pivotally connecting each of the room roof section
supports by a bolt and nut to one of said rafter beams.
34. The structure of claim 31 wherein said core roof section
comprises a plurality of rafters, said rafters comprising a pair of
metal channel beams having at least one flat side, and which pair
of beams are attached together at one end of each of said beams via
at least one bolt and nut, one of said rafter beams being notched
and the other of said rafter beams being positioned within the
notch such that said rafter beams are interlocking with one
another; and each room roof section being pivotedly connected to
the core roof section via an end of a rafter beam on the same side
of the central core as each room floor section is connected to the
core floor section.
35. The structure of claim 34 wherein the core roof section further
comprises a plurality of metal channel core roof section supports,
each one of said core roof section supports being positioned within
a notch in one of the rafters and attached to said rafter via at
least one bolt and nut such that said supports and said rafter
beams are interlocking with one another.
36. The structure of claim 34 wherein each room roof section
comprises a plurality of metal channel room roof section supports,
each room roof section being pivotedly connected to the core roof
section by pivotally connecting each of the room roof section
supports by a bolt and nut to one of said rafter beams.
37. A process for forming a prefabricated folding structure
comprising: I. providing a trailer which comprises a rectangular
framework, which framework is disposed on at least four wheels, an
upper edge of the rectangular framework comprising a channel around
a periphery of the framework; II. forming a habitable structure on
the trailer by erecting a generally rectangular central core
comprising a plurality of core walls, a lowermost portion of each
of the core walls being positioned within the channel of the
trailer framework, a core floor section connected to and extending
between the core walls at a base of the core walls, and a core roof
section connected to and over the core walls and over the core
floor section; each of said core walls, core floor section and core
roof section comprising a plurality of spaced metal channel beams
having at least one flat side; attaching a plurality of folding
rooms to the central core; each folding room comprising a plurality
of room wall members, a folding room floor section removably
attached to and extending between the room walls at a base of the
room walls and a folding a room roof section removably attached to
and extending over the room wall members and extending over the
room floor section; each of the room wall members, the room floor
section and the room roof section comprising a plurality of spaced
metal channel beams having at least one flat side; pivotedly
connecting at least one said room floor section at one end thereof
to said core floor section; at least said one room roof section
being pivotedly connected at one end thereof to said core roof
section; said room wall members being removably attached to said
room floor section and said room roof section; each room roof
section being pivotedly connected to the core roof section on the
same side of the central core as each room floor section is
connected to the core floor section; wherein each folding room
floor section and each folding room roof section may be alternately
detached from its room wall members and pivoted inwardly toward
said central core and positioned in close proximity to and
substantially parallel to a corresponding core wall and thereby
form a compact folded structure, or pivoted outwardly away from
said central core to define a room adjacent to said central core
when attached to its room wall members.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to prefabricated folding
structures, or more particularly to prefabricated residential
dwellings comprised of a prefabricated floor, wall and roof members
that fold inwardly upon itself to produce a compact partially
collapsed folded structure, which is easily transportable, and then
unfold outwardly for quick and easy on-site installation.
[0003] 2. Description of the Related Art
[0004] The vast majority of structures, particularly residential
houses, are completely constructed on-site. In the various
sequential construction stages required materials and labor are
brought to the site. A foundation is laid and the shell of the
house is framed. Thereafter, exterior walls, roofing, and floors
are installed using plywood sheets, followed by the installation of
exterior siding and roof shingles. Windows, heating, electrical and
plumbing systems are installed by heating contractors, electricians
and plumbers. Insulation is added followed by installation of all
the interior walls and floors. Thereafter, appliances are
positioned and connected to the electrical and plumbing systems.
Interior finishing work such as painting, wall-papering, and
interior trim follow. While on-site construction, is the
predominant form of house construction, such entail considerable
labor costs. It would be desirable to reduce construction costs by
taking advantage of the economies of scale available with factory
prefabricated housing.
[0005] Prefabricated building structures are well known and the
majority of these comprise pre-cast or pre-assembled panel
structures which are transported to an erection site and assembled.
Although many of the component parts of the buildings are
pre-fabricated, the erection time can be fairly lengthy and
inclement weather conditions can further slow down the erection
time as well as expose building materials to the elements. Often,
the pre-assembled parts are difficult to transport, heavy to
manipulate and often require the use of large cranes for assembly.
Prior alternatives involve prefabricating various portions of a
house at a central facility or plant, transporting these portions
to a building site and then performing the remaining assembly work
on-site. It was believed that by prefabricating a significant
portion of a house, sufficient cost savings would occur so that the
purchase price of the installed prefabricated house would be less
than that of a similarly sized conventionally constructed house.
However, the installation cost of prefabricated prior art
structures was found to be substantial and, when added to the cost
of manufacture and delivery, caused the total cost of any of these
prefabricated structures to exceed that of conventional
construction. Many of the prefabricated or other type home or
building structures are constructed for permanent installation and
cannot be easily dismantled and reassembled on another site. A
still further disadvantage of prefabricated structures is that
often these are not very structurally sound and can become damaged
if exposed to tornadoes or hurricane force winds. Some of these are
also not well insulated or resistant to insect infestation such as
by termites. Still further prefabricated building structures
require expensive foundations made of concrete thereby increasing
the cost of the prefabricated structure. U.S. Pat. No. 6,253,521
shows a steel-framed building construction. A number of
prefabricated sections are assembled on a construction site,
however, such is not foldable. U.S. Pat. No. 5,950,373 shows a
transportable structure kit. All of the parts for a disassembled
housing structure are placed in a transportable container for
subsequent assembly. U.S. Pat. No. 6,295,766 shows a multistory,
modular building structure which may be mounted on a trailer,
however such is not indicated to be foldable. U.S. Pat. No.
5,960,593 shows a transportable and collapsible building, however,
such is for temporary use as a bar, or the like, for example at
sporting functions. Such is not habitable. This invention improvers
on U.S. Pat. Nos. 4,545,171; 4,660,332 and 3,348,344, all of which
are incorporated herein by reference, which show prefabricated
folding structures suitable for residential housing, however, the
frameworks thereof are made of hardwood materials which are subject
to termite infestation and can become damaged if exposed to
hurricane force winds. U.S. Pat. No. 5,890,341 shows a modular,
structure, but does not mention steel framing. U.S. Pat. No.
6,434,895 shows a foldable, trailerable building which is useful as
a field office, however, no plumbing or electrical capability is
mentioned and such would not be suitable as a residential
dwelling.
[0006] It has now been found that a permanent, pre-fabricated,
modular, building may be formed from interlocking rooms using
interlocking, pivoting metal channel beams which are resistant to
insect infestation and hurricane force winds. The structure has a
number of rooms having pivotably floor, roof and wall sections
which fold upon one another and thereby form a compact folded
structure, and which when unfolded, deploy to form a habitable
structure.
SUMMARY OF THE INVENTION
[0007] The invention provides a prefabricated folding structure
comprising: [0008] a generally rectangular central core comprising
a plurality of core walls, a core floor section connected to and
extending between the core walls at a base of the core walls, and a
core roof section connected to and over the core walls and over the
core floor section; each of said core walls, core floor section and
core roof section comprising a plurality of spaced metal channel
beams having at least one flat side; [0009] a plurality of folding
rooms attached to the central core; each folding room comprising a
plurality of room wall members, a folding room floor section
removably attached to and extending between the room walls at a
base of the room walls and a folding a room roof section removably
attached to and extending over the room wall members and extending
over the room floor section; each of the room wall members, the
room floor section and the room roof section comprising a plurality
of spaced metal channel beams having at least one flat side; [0010]
at least one said room floor section being pivotedly connected at
one end thereof to said core floor section; at least said one room
roof section being pivotedly connected at one end thereof to said
core roof section; said room wall members being removably attached
to said room floor section and said room roof section; each room
roof section being pivotedly connected to the core roof section on
the same side of the central core as each room floor section is
connected to the core floor section; wherein each folding room
floor section and each folding room roof section may be alternately
detached from its room wall members and pivoted inwardly toward
said central core and positioned in close proximity to and
substantially parallel to a corresponding core wall and thereby
form a compact folded structure, or pivoted outwardly away from
said central core to define a room adjacent to said central core
when attached to its room wall members.
[0011] The invention also provides a multistory prefabricated
folding structure comprising: [0012] a generally rectangular
central core comprising a plurality of core walls, a core floor
section connected to and extending between the core walls at a base
of the core walls, and a core roof section connected to and over
the core walls and over the core floor section; each of said core
walls, core floor section and core roof section comprising a
plurality of spaced metal channel beams having at least one flat
side; [0013] a plurality of folding rooms attached to the central
core; each folding room comprising a plurality of room wall
members, a folding room floor section removably attached to and
extending between the room walls at a base of the room walls and a
folding a room roof section removably attached to and extending
over the room wall members and extending over the room floor
section; each of the room wall members, the room floor section and
the room roof section comprising a plurality of spaced metal
channel beams having at least one flat side; [0014] at least one
said room floor section being pivotedly connected at one end
thereof to said core floor section; at least said one room roof
section being pivotedly connected at one end thereof to said core
roof section; said room wall members being removably attached to
said room floor section and said room roof section; each room roof
section being pivotedly connected to the core roof section on the
same side of the central core as each room floor section is
connected to the core floor section; [0015] a sub-core attached
under the central core, said sub-core comprising a generally
rectangular central sub-core comprising a plurality of sub-core
walls, a sub-core floor section connected to and extending between
the sub-core walls at a base of the sub-core walls, each of said
sub-core walls and the sub-core floor section comprising a
plurality of spaced metal channel beams having at least one flat
side; [0016] a plurality of folding sub-rooms, one folding sub-room
attached under one of the folding rooms and also attached to the
central sub-core; each folding sub-room comprising a plurality of
sub-room wall members, and a folding sub-room floor section
removably attached to and extending between the sub-room walls at a
base of the sub-room walls; each of the sub-room wall members and
the sub-room floor section comprising a plurality of spaced metal
channel beams having at least one flat side; [0017] at least one
said sub-room floor section being pivotedly connected at one end
thereof to said sub-core floor section; said sub-room wall members
being removably attached to said sub-room floor section; [0018]
wherein each folding room floor section and each folding room roof
section may be alternately detached from its room wall members and
pivoted inwardly toward said central core or central sub-core and
positioned in close proximity to and substantially parallel to a
corresponding core wall or sub-core wall and thereby form a compact
folded structure, or pivoted outwardly away from said central core
to define a room adjacent to said central core when attached to its
room wall members; [0019] wherein each folding sub-room floor
section may be alternately detached from its sub-room wall members
and pivoted inwardly toward said central sub-core and positioned in
close proximity to and substantially parallel to a corresponding
sub-core wall and thereby form a compact folded structure, or
pivoted outwardly away from said central sub-core to define a room
adjacent to said central sub-core when attached to its sub-room
wall members.
[0020] The invention further provides a three-story prefabricated
folding structure comprising: [0021] a generally rectangular
central core comprising a plurality of core walls, a core floor
section connected to and extending between the core walls at a base
of the core walls, and a core roof section connected to and over
the core walls and over the core floor section; each of said core
walls, core floor section and core roof section comprising a
plurality of spaced metal channel beams having at least one flat
side; [0022] a plurality of folding rooms attached to the central
core; each folding room comprising a plurality of room wall
members, a folding room floor section removably attached to and
extending between the room walls at a base of the room walls and a
folding a room roof section removably attached to and extending
over the room wall members and extending over the room floor
section; each of the room wall members, the room floor section and
the room roof section comprising a plurality of spaced metal
channel beams having at least one flat side; [0023] at least one
said room floor section being pivotedly connected at one end
thereof to said core floor section; at least said one room roof
section being pivotedly connected at one end thereof to said core
roof section; said room wall members being removably attached to
said room floor section and said room roof section; each room roof
section being pivotedly connected to the core roof section on the
same side of the central core as each room floor section is
connected to the core floor section; [0024] a sub-core attached
under the central core, said sub-core comprising a generally
rectangular central sub-core comprising a plurality of sub-core
walls, a sub-core floor section connected to and extending between
the sub-core walls at a base of the sub-core walls, each of said
sub-core walls and the sub-core floor section comprising a
plurality of spaced metal channel beams having at least one flat
side; [0025] a plurality of folding sub-rooms, one folding sub-room
attached under one of the folding rooms and also attached to the
central sub-core; each folding sub-room comprising a plurality of
sub-room wall members, and a folding sub-room floor section
removably attached to and extending between the sub-room walls at a
base of the sub-room walls; each of the sub-room wall members and
the sub-room floor section comprising a plurality of spaced metal
channel beams having at least one flat side; [0026] at least one
said sub-room floor section being pivotedly connected at one end
thereof to said sub-core floor section; said sub-room wall members
being removably attached to said sub-room floor section; [0027]
wherein each folding room floor section and each folding room roof
section may be alternately detached from its room wall members and
pivoted inwardly toward said central core or central sub-core and
positioned in close proximity to and substantially parallel to a
corresponding core wall or sub-core wall and thereby form a compact
folded structure, or pivoted outwardly away from said central core
to define a room adjacent to said central core when attached to its
room wall members; [0028] wherein each folding sub-room floor
section may be alternately detached from its sub-room wall members
and pivoted inwardly toward said central sub-core and positioned in
close proximity to and substantially parallel to a corresponding
sub-core wall and thereby form a compact folded structure, or
pivoted outwardly away from said central sub-core to define a room
adjacent to said central sub-core when attached to its sub-room
wall members; [0029] a second sub-core attached under the sub-core,
said second sub-core comprising a generally rectangular central
second sub-core comprising a plurality of second sub-core walls, a
second sub-core floor section connected to and extending between
the second sub-core walls at a base of the second sub-core walls,
each of said second sub-core walls and the second sub-core floor
section comprising a plurality of spaced metal channel beams having
at least one flat side; [0030] a plurality of folding second
sub-rooms, one folding second sub-room attached under one of the
folding sub-rooms and also attached to the central second sub-core;
each folding second sub-room comprising a plurality of second
sub-room wall members, and a folding second sub-room floor section
removably attached to and extending between the second sub-room
walls at a base of the second sub-room walls; each of the second
sub-room wall members and the second sub-room floor section
comprising a plurality of spaced metal channel beams having at
least one flat side; [0031] at least one said second sub-room floor
section being pivotedly connected at one end thereof to said second
sub-core floor section; said second sub-room wall members being
removably attached to said second sub-room floor section; [0032]
wherein each folding room floor section and each folding room roof
section may be alternately detached from its room wall members and
pivoted inwardly toward said central core or central sub-core and
positioned in close proximity to and substantially parallel to a
corresponding core wall or sub-core wall and thereby form a compact
folded structure, or pivoted outwardly away from said central core
to define a room adjacent to said central core when attached to its
room wall members; [0033] wherein each folding sub-room floor
section may be alternately detached from its sub-room wall members
and pivoted inwardly toward said central sub-core and positioned in
close proximity to and substantially parallel to a corresponding
sub-core wall and thereby form a compact folded structure, or
pivoted outwardly away from said central sub-core to define a room
adjacent to said central sub-core when attached to its sub-room
wall members; [0034] wherein each folding second sub-room floor
section may be alternately detached from its second sub-room wall
members and pivoted inwardly toward said central second sub-core
and positioned in close proximity to and substantially parallel to
a corresponding second sub-core wall and thereby form a compact
folded structure, or pivoted outwardly away from said central
second sub-core to define a room adjacent to said central second
sub-core when attached to its second sub-room wall members.
[0035] The invention also provides a process for forming a
prefabricated folding structure comprising:
[0036] I. providing a trailer which comprises a rectangular
framework, which framework is disposed on at least four wheels, an
upper edge of the rectangular framework comprising a channel around
a periphery of the framework;
[0037] II. forming a habitable structure on the trailer by erecting
a generally rectangular central core comprising a plurality of core
walls, a lowermost portion of each of the core walls being
positioned within the channel of the trailer framework, a core
floor section connected to and extending between the core walls at
a base of the core walls, and a core roof section connected to and
over the core walls and over the core floor section; each of said
core walls, core floor section and core roof section comprising a
plurality of spaced metal channel beams having at least one flat
side; [0038] attaching a plurality of folding rooms to the central
core; each folding room comprising a plurality of room wall
members, a folding room floor section removably attached to and
extending between the room walls at a base of the room walls and a
folding a room roof section removably attached to and extending
over the room wall members and extending over the room floor
section; each of the room wall members, the room floor section and
the room roof section comprising a plurality of spaced metal
channel beams having at least one flat side; [0039] pivotedly
connecting at least one said room floor section at one end thereof
to said core floor section; at least said one room roof section
being pivotedly connected at one end thereof to said core roof
section; said room wall members being removably attached to said
room floor section and said room roof section; each room roof
section being pivotedly connected to the core roof section on the
same side of the central core as each room floor section is
connected to the core floor section; wherein each folding room
floor section and each folding room roof section may be alternately
detached from its room wall members and pivoted inwardly toward
said central core and positioned in close proximity to and
substantially parallel to a corresponding core wall and thereby
form a compact folded structure, or pivoted outwardly away from
said central core to define a room adjacent to said central core
when attached to its room wall members.
[0040] Thus the invention provides sturdy, habitable low-cost
prefabricated structures which are not only economical to
manufacture but are also easy and inexpensive to install on-site,
to thereby provide significant cost savings over a similarly sized
conventionally constructed structure. All the necessary systems,
such as wiring, plumbing and heating, and appliances in the
structure during prefabrication.
[0041] Thus the need for heavy machinery during installation of the
structure as well as the labor and effort required for installation
are minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 is a perspective view of the outside of the inventive
prefabricated folding structure shown in a completely folded
shipping configuration.
[0043] FIG. 2 is a cross-sectional view of applicant's
prefabricated folding structure, depicting the pivotal movement of
the folding roof sections.
[0044] FIG. 3 is a cross-sectional view of the prefabricated
folding structure, depicting the pivotal movement of folding floor
members.
[0045] FIG. 4 is a plan elevational view of the interior of the
prefabricated folding structure, depicting the movement of exterior
side walls 91, 92, 93 and 94 during erection.
[0046] FIG. 5 is an exterior perspective view of the prefabricated
structure shown completely unfolded and installed on-site.
[0047] FIG. 6 is a cross-sectional view of an alternate embodiment
of a single story prefabricated structure, shown completely
unfolded.
[0048] FIG. 7 is a cross-sectional view of a multi (two) story
prefabricated house shown completely unfolded.
[0049] FIGS. 8A and 8B show beams have a generally U-shaped or
C-shaped cross-section.
[0050] FIG. 9 illustrates an interlocking of rafter beams wherein
adjacent beams have their edge flanges cut away and one beam rests
on the other prior to bolting together.
[0051] FIG. 10 illustrates an interlocking of a stud to a beam
wherein a notch is cut into a bolt edge flange, a stud is
positioned within the notch and rests on the opposite bolt flange
prior to the stud and beam being bolted together.
[0052] FIG. 11 illustrates a trailer having a channeled framework
on which a habitable structure according to the invention may be
built.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0053] The present invention is applicable to a wide variety of
structures of different weight, size, shape and materials for a
variety of diverse uses. The invention pertains to single story as
well as multiple story prefabricated residential dwellings
constructed from interlocking rooms.
[0054] FIG. 1 shows an exterior perspective view of a single-story
prefabricated folding house constructed in accordance with the
invention and folded into a shipping configuration. As shown, the
house contains a generally rectangularly shaped prefabricated
central core 5, of which only exterior core wall 21 is shown.
Positioned substantially parallel to and alongside this core wall,
are the front and rear walls and pivoting floor sections.
[0055] On the sides of the core, exterior side walls 71, 72 having
corners 3, are adjacent to pivoting floor section 61 at floor joist
611. Each of these joists in the pivoting floor sections are
pivotedly connected at an end, via pivots 2, to a respective one of
the floor joists, e.g. joist 411, which joists together comprise
the floor of the central core 5. The floor of the central core is
comprised of a plurality of beams, positioned substantially
perpendicular to the walls of the central core, at least one beam
oriented parallel to the walls of the central core connected to
each of the plurality of beams, and acceptable decking material
attached to and substantially covering the beams.
[0056] Preferably, these beams are made of steel, and the decking
material can be plywood or fiberboard. The preferred material
comprises steel studs enclosing polystyrene foam panels or
sections, such as are available commercially from ThermaSteel
Corporation of Radford, Va. Panels, such as 4 foot by 8 foot panels
may be formed by setting steel studs in a forming jig and then
filling the cavity with expanded polystyrene. The polystyrene
protects the steel and greatly adds to the thermal insulation value
of the structure. In a particularly advantageous embodiment, the
decking comprises a subflooring of plywood or the like, followed by
a final floor covering of hardwood planking, carpeting, tile or
linoleum, depending upon the use for that particular section of the
house.
[0057] The beams of the central core floor 41 (FIG. 2), are
C-shaped or U-shaped metal joists, which are preferably steel. All
the joists comprising these floor members are arranged in an
approximate 16'' center-to-center spacing and are staggered such
that an end of each floor joist in each pivoting floor member lies
adjacent to an end of a corresponding floor joist in the central
core. During prefabrication, both subflooring, of illustratively
5/8'' thick plywood, and final floor covering, of illustratively
1/4'' hardwood planking, are attached over all the joists
comprising each of these floor members with exception of an area
above pivots 2 between each pivoting floor section and the core
floor. Affixed atop the central core is a ceiling member upon which
is positioned a plurality of prefabricated roof trusses, of which
only truss 31 is shown. When a folding structure is used as a
single story dwelling or the top floor of a multiple story
dwelling, these trusses provide support for the folding roof which
is comprised of lower folding roof sections 51 and 52 and upper
folding roof sections 50 and 53. Each lower roof section is
pivotedly connected at one of its ends to both an end of a
respective upper folding roof section and to an end of each truss.
In the shipping configuration as shown, the lower folding roof
sections are pivotedly oriented downward to lie alongside the
pivoting floor section, and the upper folding roof sections are
pivotedly oriented downward to lie against each of the trusses.
These folding roof sections preferably comprise a plurality of
rafters positioned substantially perpendicular to the walls of the
core, at least one rafter positioned perpendicular to the plurality
of rafters for connection thereto, a sheathing material connected
to and substantially covering the rafters and moisture barrier
means attached to the sheathing. The moisture barrier is preferably
builder felt, and a building exterior, such aluminum siding, PVC
siding, shingles, cedar shakes, bricks, etc., is placed upon the
moisture barrier and sheathing materials. Since the weight of the
folding structure is primarily supported by the walls of the
central core, relatively little weight is borne by any of the wall,
and pivoting floor and pivoting roof members. Consequently, these
pivoting members can be made light in weight. Not only does this
advantageously eliminate the need to use a reinforced foundation,
but, in addition, this advantageously minimizes the effort required
to pivotally move these members into proper position during
installation of the structure. Thus, once the structure is properly
positioned on its foundation, only a minimum amount of labor and no
heavy machinery is needed to unfold the structure and complete the
installation. These factors, coupled with the use of only
inexpensive standard building materials and extensive
prefabrication, advantageously permit substantial cost savings to
be achieved over the cost of both prior art prefabricated
structures and conventional construction. The use of pivoting
floor, pivoting roof and movable walls, which fold and unfold,
reduces the height and width of the folded home to specifically 11
feet 4 inches and 13 feet 8 inches, respectively. Advantageously,
this greatly lowers the center of gravity of the folded home.
Consequently, this ensures that the house is not susceptible to
being tipped over during shipment. Hence, the house can be easily
and safely transported on a flatbed truck to a suitable building
site. In a preferred embodiment of the invention, the entire
building is constructed on a wheeled trailer, which is may be used
to drive the partially built structure from assembly station to
assembly station, and ultimately to the final installation
site.
[0058] Once a suitable site has been appropriately excavated, a
concrete foundation is laid. This foundation is provided with four
points for supporting the folding structure. Two supports are
located just below and outside of the core walls, and each of the
two other supports is located under one of the pivoting floor
sections. Thus, the two supports for the core hold the weight of
the structure while the pivoting floor supports maintain the floor
in the correct orientation and position i.e., parallel to and level
with the core floor. A plate (not shown), which may be comprised of
a pair of studs laid one atop another, is affixed all around the
top surface of this foundation. These studs and the foundation are
configured and arranged so as to facilitate the unfolding of the
structure. Preferably, the core walls each comprise a plurality of
steel studs and at least two plate members connected respectively
to the top and bottom of the plurality of studs. Since these core
walls are located within the folded structure, they are provided
with gypsum board after the necessary piping, plumbing, and
electrical components have been installed. An advantageous stud is
a steel, although aluminum, or other metals could be used, if
desired. Thereafter, the folded house shown in FIG. 1 is positioned
on top of the plate and unfolded in a manner discussed below.
[0059] FIG. 2 depicts a cross-sectional view of the prefabricated
folding house of FIG. 1. FIGS. 1 and 2 show that the folding house
is comprised of a rectangularly shaped central core 5, a plurality
of detachable and movable exterior wall members 71 and 72, pivoting
floor sections 61 and 62; folding upper and lower roof section 50
and 53, and 51 and 52, respectively; and pivoting ceiling members
81 and 82, a plurality of prefabricated roof trusses of which only
truss 31 is shown and ridge beam 56. Central core 5 is comprised of
interior core walls 22, 23, 24, 26, 27 and 28, movable and
detachable side walls 91, 92, 93 and 94, and exterior core walls 21
and 25 all secured, both core floor 41 and ceiling member 40 as
shown in FIGS. 2, 3 and 4. The central core is completely
prefabricated and contains all piping, plumbing, and electrical
control means (i.e.--circuit breaker box, etc.) for connection to
external sources of supply (i.e. water, gas, electricity, etc.).
Also, all necessary systems for the entire structure, e.g. heating,
plumbing and electrical, and all the required appliances and
plumbing fixtures are installed in the central core during
prefabrication. Furthermore, any outlets that are to be located in
any of the pivoting members, particularly the walls, are installed
while the structure is being prefabricated.
[0060] As shown in FIG. 4, the core contains the kitchen including
all its appliances; the bathroom--including the necessary plumbing
fixtures, including a bathroom sink, tub/shower and toilet; and a
closet with folding doors containing the hot water heater, washer
and dryer. Each pivoting exterior wall (front wall 71, rear wall 72
and side walls 91, 92, 93 and 94) is completely assembled during
pre-fabrication. These walls would be constructed in the same
manner as the core walls. One difference, however, is that these
walls would each have one side facing the exterior of the building.
These faces would then be covered with a sheathing, moisture
barrier, and finally, the desired exterior facade.
[0061] Each wall is specifically fabricated from steel studs which
are approximately spaced 16'' apart on a center-to-center basis.
During prefabrication, windows are installed at predetermined
locations into these walls, and the exterior surface of each
folding wall, i.e., that surface which faces the outside
environment, is covered with standard 1/2'' plywood sheathing
material over which a moisture barrier along with the desired
siding material, e.g. aluminum siding, PVC siding, asbestos shingle
or other siding material, is applied. In addition, electrical
outlet boxes are affixed to various studs in these walls and wired
at the factory. To conform with standard building codes, all
electrical wiring is placed inside each wall. Thereafter, thermal
insulation is installed within each wall and illustratively 1/2''
gypsum board, (also known as "dry wall" or "sheet rock") is then
installed over the interior surface of each folding exterior wall,
with an appropriately located prewired electrical outlet. If
polystyrene embedded steel panels are used, such extra insulation
may be eliminated. Roof and ceiling supporting structures are
provided above the central core. These are located on and are
supported by the common walls of the core, and preferably comprise
a plurality of prefabricated steel truss assemblies. Each of the
prefabricated trusses provide the necessary structural support for
the upper and lower folding roof sections whenever they are pivoted
into an open, i.e. unfolded, position. While only one truss 31 is
shown in the cross-sectional view of FIG. 2, the house is
illustratively comprised of a number of separate trusses, each
fabricated from rafters and mounted on a 24'' center to center
spacing. Any number of trusses can be used, with the particular
number being predicated upon the desired spacing between trusses
and the size of the structure. The spacing for the trusses (and
also for the floor joists, wall studs and ceiling rafters) is often
specified by local building codes and/or practice and can thus vary
from that specified below. Each truss is pivotedly attached to
upper roof sections 50 and 53, and lower roof sections 51 and 52 of
the roof. As shown in FIGS. 2 and 4, a number of structural
members, including exterior side and front and rear walls and a
pivoting floor member, are positioned during prefabrication
substantially parallel to and alongside the interior core walls.
These structural members are arranged in two groups of similar
members, group 7 being adjacent to interior wall 28 and the other,
group 8, being adjacent to interior wall 22. In the shipping
configuration shown in FIG. 1, the structural members comprising
each group are positioned alongside each other and are all
substantially parallel to the adjacent interior core wall 22 or 28.
Group 7 is comprised of free-standing partition 105, exterior side
wall 91, exterior front wall 71 and pivoting floor section 61, and
also, as is apparent from FIG. 4, walls 102-104 and exterior side
wall 94. Group 8 is comprised of similar structural members and
free-standing partitions, specifically, exterior side walls 92 and
93, exterior rear wall 72, pivoting floor section 62, interior
walls 108-112 and free standing partitions 106 and 107. It should
be noted that interior walls are joined together, but are provided
with an open area in between for access (i.e., a doorway). The same
applies to wall 103 and 104; 108 and 110; and 109 and 111.
[0062] In accordance with this feature of the invention,
substantial closet space is incorporated into the folding structure
through the use of the folding interior walls and free-standing
partitions. When the structure is fully folded, these interior
walls and partitions are initially positioned to lie alongside
various interior side walls comprising the central core. Once the
walls and floor members are pivoted into their properly installed
positions, an enclosed area is defined around the core. Each
pivoting interior wall and each free-standing partition are then
pivoted or moved to a pre-determined position within this area in
order to define all the rooms arranged about the core and all the
closets existing therein.
Folding the Structure
[0063] The shipping configuration, shown in FIG. 1, is achieved
during prefabrication by removing the interior walls and
positioning the free-standing partitions against the core walls and
positioning the various structural members inwardly about the
central core.
[0064] First, free-standing partition 105 is positioned, alongside
interior side core wall 28. This partition is preferably oriented
such that its vertical edges are parallel to those of the interior
core wall. In a similar fashion, interior walls 101-104 are
positioned, as shown in FIG. 4, such that each lie alongside
interior side core walls 26 and 27.
[0065] Thereafter, folding ceiling members 81 and 82 are each
pivotedly positioned upwardly, as shown in FIG. 2, such that each
folding ceiling member, e.g. ceiling member 81, lies partially
within and parallel to a corresponding lower folding roof member,
e.g. folding roof member 51. The rafters in each folding ceiling
member are staggered with respect to those in each corresponding
lower folding roof member such that when those ceiling members are
folded their joints partially interleave with those in each
corresponding lower roof folding section.
[0066] Next, as shown in FIG. 4, exterior side walls 91 and 94 are
positioned inwardly, about corners 4, such that these walls lie
alongside free-standing partitions 105 and wall 101, respectively.
Then, exterior front wall 71 is positioned downward, such that it
lies alongside pivoting floor section 61.
[0067] Thereafter, pivoting floor section 61 is pivoted upward
about pivot 2 located in the left end of core floor 41, such that
exterior front wall 71, particularly its exterior surface, lies
alongside exterior side wall 91 (and 94 not shown). Now, with all
the exterior walls positioned inwardly about the core, upper
folding roof section 50 and 53 are folded, as shown in FIG. 2, by
being pivotedly positioned downward until each abuts against all
the trusses, e.g. truss 31. Lower folding roof sections 51 and 52
are then folded by being pivotedly positioned downward and inwardly
such that each lies vertically alongside folded floor members 61
and 62, respectively. The pivots 2 between folding floor members 61
and 62 and core floor 41 provides a for rotation of the pivoting
floor section with respect to the central core floor, means for
transferring the load from the pivoting floor section to the
central core floor and provides a means for reducing frictional
forces during rotation of the pivoting floor section. The pivoting
means is preferably bolting means or the like. Specifically, this
pivoting assembly may be a 1/2'' ASTM A307 bolt secured by washers
and a nut. Similar pivots are between folding roof sections 51 and
52 and core 5.
Unfolding the Structure
[0068] Having summarily described the sequence in which the walls
are positioned, and the folding floor and roof members fold
inwardly about the central core to form the folded structure shown
in FIGS. 1-3, an explanation will now be given as to the manner in
which the structural members are sequentially unfolded and
interlocked to transform the house from its shipping, i.e., folded,
configuration into a fully habitable residential dwelling as shown
in FIG. 5.
[0069] The first structural members to be unfolded are the roof
sections. As shown in FIG. 2, upper folding roof sections 50 and 53
are pivotedly positioned upward and outward. Ridge beam 56 is
preferably a steel beam which runs the entire length of upper
folding roof section 53 and abuts against the top edge of folding
roof section 50 when both these roof sections are completely
unfolded. The rafters that comprise each of these upper roof
sections are steel beams located on a 24'' center-to-center
spacing, and all the rafters comprising either of the upper roof
sections are staggered with respect to those of the other. Once
these upper roof sections are completely unfolded into position as
shown in FIG. 2, the ridge beam and each rafter comprising folding
roof sections 50 and 53 are secured sections in position. It should
be noted that all upper roof sections have been fully sheathed and
shingled during prefabrication. Next, as shown in FIG. 2, lower
roof sections 51 and 52, each comprised of illustratively steel
rafters are pivoted upward and outward into position. These rafters
are connected by pivots comprising bolts. Each pivot connecting
both the upper and lower roof sections to the trusses, is comprised
of a series of 1/2'' bolts (not shown), each of which runs through
a rafter in a lower roof section, an adjacent truss and an adjacent
rafter in upper roof section. A temporary support (not shown) is
then positioned under the lower end of each of these lower folding
roof sections and is adjusted to an appropriate height to
temporarily keep each lower roof section in its completely unfolded
position. To secure the roof sections in a final position, a
properly sized nut which has been threaded onto the end of each
bolt is fully tightened. Again all lower roof sections have been
fully sheathed and shingled during prefabrication. Once the roof is
completely unfolded, folding floor member 61 and 62 are pivoted
into position. Specifically, both folding floor members are pivoted
downward and away from the central core, thereby forming the entire
floor for the dwelling. Thereafter, as shown in FIG. 8, exterior
front and rear walls 71 and 72 are set into position. Specifically,
each wall is positioned outward until the upper ends of exterior
front wall 71 and exterior rear wall 72 abut against all the
rafters comprising lower folding roof sections 51 and 52,
respectively. With these exterior front and rear walls secured in
place, exterior side walls 91, 92, 93, and 94, as shown in FIG. 4,
are then positioned and secured in place. Specifically, each
exterior wall is positioned such that each end wall lies
substantially perpendicular to the exterior front or rear walls.
Once each exterior side wall is properly positioned, they are
bolted to adjacent ceiling rafters and floor joists. At the end
walls of the house, the ceiling and lower roof section are
pivotally joined. The pivots utilized for this connection comprises
means for rotation of the ceiling member with respect to the roof
member, and for attaching the ceiling and roof member to the outer
wall member. At this juncture, folding ceiling members 81 and 82
are unfolded into position. To accomplish this, folding ceiling
members are pivoted downward such that unfolded ceiling member 81
lies on top of unfolded exterior front wall 71 and side walls 91
and 94; and unfolded ceiling member 82 lies on top of exterior
front wall 72 and side walls 92 and 93, respectively. Next,
exterior front wall 71 is secured to unfolded ceiling member 81 and
to lower folding roof section 51. To further secure the exterior
front wall to the lower roof section, a bolt and nut assembly (not
shown) preferably 1/2'' diameter, which has been inserted through a
pre-drilled hole and into a corresponding hole in the adjacent
lower roof rafter during prefabrication, is tightened. Appropriate
size washers may be used with each bolt. Exterior rear wall 72 is
secured to lower folding roof section 52 in a substantially
identical fashion. Since adequate support for the lower roof
members is now provided by all the exterior walls, temporary
supports, such as jacks that support these lower roof sections are
now removed.
[0070] Once the folding ceiling members have been fully unfolded
and secured in position, an enclosed area is defined about this
central core. Then, interior walls 101-104 and 108-112, and
free-standing partitions 105, 106, and 107, are moved into
respective positions in this area to define both the rooms arranged
about the central core and all the closets contained therein.
Specifically, interior walls 103 and 112 are positioned in the same
manner as does exterior side wall 92. Once the interior walls are
positioned, then each free-standing partition is appropriately
positioned in place. The interior walls and partitions are
completely framed and covered with gypsum board during
prefabrication. Once in position, each of these interior walls and
partitions are secured by bolts, nuts and washers to the floor
joists in pivoting floor sections 61 or 2, and to the rafters in
ceiling members 81 and 82. Specifically these bolts are driven
through adjacent rafters in the ceiling and between joists in the
folding floor members, and into the top (and bottom) horizontal
studs comprising each of these interior walls and partitions.
Advantageously, the use of free-standing partitions, which are
positioned during on-site installation, to define room sizes and
closets, readily permits changing the dimensions of these rooms and
closets at any time up to installation without incurring much, if
any, expense. While the doors to each of the closets formed by the
free-standing partitions, as well as a number of interior room
doors, have all been omitted for the sake of clarity from the plan
views shown in the drawing, these doors are attached, i.e.
pre-hung, to corresponding pivotal walls or free-standing
partitions and interior core walls during prefabrication.
Advantageously, this further reduces on-site installation time and
expense.
[0071] As should be readily apparent, applicant's folding
prefabricated house is now completely unfolded. At this stage of
installation, the only portion of the dwelling that remains to be
enclosed is the attic. To accomplish this, a prefabricated gable
end is fixed to the outermost roof rafters and ceiling beams
existing at each side of the dwelling. Specifically, each of the
two gable ends, of which only gable end 97 is shown in FIG. 5, is
triangularly shaped and is comprised of a series of steel studs
(not shown) of appropriate length and mounted apart from each other
on an approximate 16'' center to center spacing. A layer of
sheathing (not shown), preferably 1/2'' plywood, is installed over
these studs during prefabrication at the factory. After the gable
ends are installed on-site, appropriate siding material, e.g.
aluminum or shingle, is applied to the entire side of the house
including the gable ends. Applying this type of siding in the field
advantageously minimizes the likelihood that any misalignment
between the siding on the gable ends and that on the rest of the
exterior side walls will be visible. If, however, cedar shingles
are used for siding, then any minor misalignment between the siding
attached to the gable ends and that attached to the rest of the
exterior side walls is generally not visible. Consequently, this
siding material can be applied during prefabrication to both the
gable ends and to all the exterior side walls in order to further
reduce on-site installation time and cost. The prefabricated gable
ends, are temporarily stored in the central core (more specifically
by being placed on the floor of the core) while the folded house is
being shipped to the building site.
[0072] The last remaining stage of installation, namely interior
finishing, can now proceed. Specifically, the edges of any interior
surfaces of abutting structural members are appropriately taped,
spackled and sanded, in preparation for applying final wall
covering, e.g. paint, or wallpaper. Thereafter, subflooring and
final hardwood planking or other final flooring materials are
installed in the previously unfloored areas of the house, i.e.
above pivots 4. Alternatively, the entire sub-floors and final
floor covering can be installed on-site. While this latter approach
slightly increases installation cost, it may be necessary,
depending upon the final floor covering chosen by the owner, in
order to eliminate any visible gaps or joint lines from appearing
in the floor. Thereafter, molding and any remaining interior trim
is now installed. At this point, the dwelling has been completely
constructed and only requires connection to the local utilities,
e.g. electricity and sewerage, for it to be completely habitable.
An exterior perspective view of the dwelling as it stands
completely installed and ready for occupancy is shown in FIG.
5.
[0073] In the illustrative embodiment described herein, heat is
provided through electric baseboard. While electric heat is usually
relatively expensive to operate, it is the least expensive to
install. Consequently, separate electric baseboard units are
installed along the interior bottom edge of various interior core
walls and various folding walls. However, to minimize heating
costs, a separate thermostat is installed in each room during
prefabrication. Other types of heating, ventilating, and air
conditioning systems, where desired, can be substituted for
electric baseboard or added in addition thereto. Any desired system
can be substantially shop installed during prefabrication. In
addition, the necessary cable or wiring requirements (i.e.,
electrical, telephone, television, etc.) can be shop installed
during prefabrication. Since the weight of a residential dwelling
constructed in accordance with the teachings of the present
invention is primarily supported by the walls comprising the
central core, this advantageously permits all the pivoting
structural members to be made relatively light. Consequently, this
permits each member to be pivoted into position by a few workers
without using any heavy machinery. Furthermore, the minimal weight
inherent in the structure eliminates the need to incorporate any
columns into the structure or to construct the foundation from
reinforced concrete. Consequently, these factors advantageously
reduce installation cost.
[0074] The exterior front walls are not limited to being co-planar
when fully unfolded. The two walls making up the exterior front
wall can be staggered to create a relatively large living room, and
also lend a pleasing appearance to the front of the dwelling. In a
similar fashion, any of the other walls and/or core walls are also
not constrained to entirely lie in a single plane but can instead
by comprised of a number of staggered or otherwise non-co-planar
sections. Moreover, the pivoting floor and/or ceiling member can
also take on many varied non-co-planar geometries to create many
diverse and architecturally pleasing layouts. Consequently, a
variety of differently shaped structures, including but by no means
limited to a simple rectangular layout, can be easily fabricated
using the principles of the invention.
[0075] FIG. 6 illustrates a single story structure which can be
provided with a flat roof or used as the first or lower floors of a
multi-story structure. The single story structure or the lower
floors of the multi-story structure are not provided with folding
roofs or roof trusses, but instead have ceiling members 40a only in
the area of the central core. Then, when such structure is to be
used as a single story house, ceiling members 81a, 82a for the
rooms adjacent to the central core are installed.
[0076] These members 81a, 82a shown in phantom in FIG. 6 may be
pivotally connected to ceiling members 40a in the same manner as
the pivoting floor sections are connected to the core floor.
Alternately, these ceiling members 81a, 82a may be field installed.
In either embodiment, these ceiling members are partially supported
at their opposite end by a pivotable wall member. Then, a flat or
conventional roof can be constructed upon these ceiling members
40a, 81a, 82a to complete the single story structure. For
multi-story, construction, the lower structures are not provided
with such ceiling members 81a, 82a, since the floors of the
adjacent upper structure 61, 62 become the ceiling members for the
lower structure. For multi-story fabrication, it is advantageous to
use steel beams 40a positioned upon the central core and to stagger
the position of these beams with respect to the position of the
floor joists 40 of the upper structure. Also, these beams extend
slightly beyond the width of the central core 5 so as to provide
enough area to pivotally connect the folding side and internal wall
members. In this construction, the floor joists 40 of the upper
structure will be positioned between the steel beams 40a of the
lower structure. Also, the core walls, 22, 28 are sufficiently
sized to support the weight of the upper structure. Then, as
mentioned above, the floor members 61, 62 of the upper structure
become the ceiling members of the lower structure.
[0077] Specifically, to construct a two-story residential dwelling
as shown in FIG. 7, two folding structures--an upper and a lower of
the type described previously, are stacked on top of each other.
The main difference between these structures is that the lower
structure does not contain a roof and appears substantially as
shown in FIG. 6. At the time of on-site installation, the lower
structure is first appropriately positioned on the foundation, and
is then completely unfolded. All the folding structural members of
the lower structure are then secured in position. As shown in FIG.
6, the lower folding structure is provided with 2''.times.10''
ceiling beams 40a straddling the central core. As mentioned above
these 2''.times.10'' beams are positioned in a staggered
configuration such that they would not be directly under the floor
joists of the upper structure. Then, the upper structure, in a
completely folded position, is placed above the lower structure and
the floor joists of the upper structure are supported by the walls
of central core of the lower structure. In this arrangement, the
floor joists of the upper structure 61, 62 become the ceiling
rafters of the lower structure. All the ceiling beams 40a of the
lower structure thus abut against and are attached to the central
core floor joists using appropriately sized nailing plates and
nails. The remaining folding structural members of the upper
structure are unfolded into position and secured as described
hereinabove.
[0078] Appropriate openings are provided both in the ceiling of the
central core of the lower structure and in the core floor member of
the upper structure during their prefabrication in order to
accommodate a stair case, which can be installed in the lower
structure during its prefabrication. Any necessary banisters and
the like are installed during the final interior finishing stage of
on-site installation. Unless the two-story dwelling is to be a two
family-house, there is little if any need to include any appliances
and/or a hot water heater in the upper structure. Thus, the area
reserved for the kitchen and closet in the central core can be
converted into other usable space, e.g. a den or study. The
technique of this invention may be used to form a single family
home, a town home, a two story colonial style dwelling, among
others.
[0079] As can be readily appreciated by those skilled in the art,
multi-story structures in excess of two stories, such as three
stories can be easily constructed in a similar manner to that
described above. The number of separate folding structures that can
be stacked to form the multi-story structure is essentially
determined by the weight of each folding structure, and the amount
of weight that can be supported by both the foundation and the
walls in each folding structure, particularly the lowest in the
stack.
[0080] The beams and studs used herein are metal channel beams,
preferably steel channel beams having at least one flat side. The
beams have a generally U-shaped cross-section with a wide flat side
150 extending to opposite perpendicular edges 152 as shown in FIG.
8A, or C-shaped cross-section with a wide flat side extending to
opposite perpendicular edges having perpendicularly inwardly
positioned edge flanges 154 as shown in FIG. 8B. Widths may range
from about 6 inches to about 12 inches. Edges may have a height of
from about 13/8 inch to about 31/2 inches. Edge flanges may range
from 0 to 1 inch. Typical material thickness ranges from 18 gauge
to 12 gauge, i.e. from about 0.046 inch to about 0.117 inch (about
1.184 mm to about 2.982 mm). Such may be made from galvanized or
carbon steel coil or sheets using a Knudson Model KR-612H,
available from Knudson Manufacturing, Inc of Broomfield, Colo. In
an important embodiment of the invention, the beams and studs of
the structure are connected by interlocking them together such as
by fitting one beam or stud into a notch in an adjacent beam. FIG.
9 illustrates an interlocking of rafter beams wherein adjacent
beams 156, 158 have their edge flanges cut away and one beam rests
on the other prior to bolting together. FIG. 10 illustrates an
interlocking of a stud 160 to a beam 162 wherein a notch 164 is cut
into an edge flange, a stud 160 is positioned within the notch 164
and rests on the opposite flange prior to the stud and beam being
bolted together. In another preferred embodiment, the bolts,
especially the bolts which act as pivots are locked into the
structural members which they connect by being surrounded by
self-tapping screws.
[0081] While the pivoting structural members, i.e. the walls,
floors, ceiling and roof members, have been described above as
folding and unfolding in a particular sequence, it is readily
apparent to those skilled in the art that any or all of these
structural members can be readily folded and unfolded in a variety
of different sequences. The particular sequence is determined by
the desired volume of the folded structure and the particular
materials used for the folding members and manner in which these
members are constructed.
[0082] FIG. 11 shows a trailer 202 on which the habitable structure
of the invention may be built. The trailer comprises a rectangular
framework 204 which is on at least four wheels. An upper edge of
the rectangular framework comprising a channel 206 around a
periphery of the framework. A habitable structure may be formed on
the trailer by erecting a generally rectangular central core
section of the previously described building within the channel
206. A lowermost portion of each of the core walls is positioned
within the channel 206 of the trailer framework 204. The core is
then erected on the trailer framework within channel 206 and then
the folding rooms are added. This technique allows movement of the
partially erected building structure from work station to work
station within a suitable factory and then allows hauling of the
finished structure to the final destination site, at which point it
is lifted out of the trailer.
[0083] While the present invention has been particularly shown and
described with reference to preferred embodiments, it will be
readily appreciated by those of ordinary skill in the art that
various changes and modifications may be made without departing
from the spirit and scope of the invention. It is intended that the
claims be interpreted to cover the disclosed embodiment, those
alternatives which have been discussed above and all equivalents
thereto.
* * * * *