U.S. patent application number 13/877096 was filed with the patent office on 2014-03-06 for buildings formed from complementary building modules, and methods for building same.
The applicant listed for this patent is Kevin Deng, Dennis Michaud, Elizabeth Rothwell. Invention is credited to Kevin Deng, Dennis Michaud, Elizabeth Rothwell.
Application Number | 20140059947 13/877096 |
Document ID | / |
Family ID | 44786122 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140059947 |
Kind Code |
A1 |
Rothwell; Elizabeth ; et
al. |
March 6, 2014 |
Buildings Formed From Complementary Building Modules, And Methods
For Building Same
Abstract
Buildings are described that incorporate at least a folding
building module and a complementary building module that also can
be a folding building module. The building modules can be shipped
to the building site separately and can be unfolded and connected
quickly. The described foldable houses and buildings exhibit more
design flexibility, are formed from easily transported building
modules, and/or allow folded building modules that are
substantially in finished condition. Additionally, methods for
forming the buildings and houses are described.
Inventors: |
Rothwell; Elizabeth;
(Philadelphia, PA) ; Deng; Kevin; (Oakland,
CA) ; Michaud; Dennis; (Groton, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rothwell; Elizabeth
Deng; Kevin
Michaud; Dennis |
Philadelphia
Oakland
Groton |
PA
CA
MA |
US
US
US |
|
|
Family ID: |
44786122 |
Appl. No.: |
13/877096 |
Filed: |
September 30, 2011 |
PCT Filed: |
September 30, 2011 |
PCT NO: |
PCT/US11/54348 |
371 Date: |
November 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61388673 |
Oct 1, 2010 |
|
|
|
Current U.S.
Class: |
52/79.5 ;
52/745.14 |
Current CPC
Class: |
E04B 1/34357 20130101;
E04H 1/005 20130101; E04B 1/3442 20130101 |
Class at
Publication: |
52/79.5 ;
52/745.14 |
International
Class: |
E04B 1/343 20060101
E04B001/343; E04H 1/00 20060101 E04H001/00 |
Claims
1. A building formed at least in part from a first unfolded
building module connected to a complementary building module.
2. The building of claim 1, wherein the complementary building
module is a second unfolded building module.
3. The building of claim 1, wherein the complementary building
module includes a panel having a first side and an opposing second
side, and the first side provides an interior surface in the
complementary building module and the second side provides and
interior surface in the first unfolded building module.
4. The building of claim 1, having a steel structural frame,
wherein a plurality of connected complementary unfolded building
modules provide substantially all of the steel structural frame of
the building.
5. The building of claim 1, wherein a first structural load
carrying member of a panel of the first unfolded building module
and a second structural load carrying member of a panel of the
connected complementary building module form a combined structural
load carrying member.
6. The building of claim 1, wherein the first unfolded building
module and the complementary building module are structurally
interdependent.
7. The building of claim 1, wherein the first unfolded building
module and the complementary building module are connected without
substantial structural redundancy.
8. The building of claim 1, wherein the first unfolded building
module and the complementary building module, when not connected,
are not independently structurally stable.
9. The building of claim 1, wherein the first unfolded building
modules, in unconnected and folded configuration, exhibits a
box-type shape.
10. The building of claim 1, wherein the first unfolded building
module has a core part and an unfolded part connected to the core
part.
11. The building of claim 10, wherein the complementary building
module is a second unfolded building module, and (i) the unfolded
part of the first unfolded building module is connected to a
complementary core part of the second unfolded building modules, or
(ii) the core part of the first unfolded building module is
connected to a complementary core part of the second unfolded
building modules.
12. The building of claim 1, wherein the first unfolded building
module and the complementary building module are connected at one
side and positioned such to share only part of the side.
13. The building of claim 1, wherein the first unfolded building
module and the complementary building module are connected through
a plurality of connection assemblies that (i) form from
complementary panels of the building modules, and (ii) are in
substantially finished condition when the panels are connected.
14. A house formed at least in part from a first unfolded building
module and a connected complementary second unfolded building
module, wherein the first unfolded building module and the second
unfolded building module, each independently, have a core part and
an unfolded part attached to the respective core part; i) the
unfolded part of the first unfolded building module is connected to
a complementary core part of the second unfolded building module,
ii) the unfolded part of the first unfolded building module is
connected to the complementary unfolded part of the second unfolded
building module, or iii) the core part of the first unfolded
building module is connected to a complementary core part of the
second unfolded building module; and the first unfolded building
module and/or the second unfolded building module contain kitchen
elements and/or bathroom elements in one or both of the respective
core structures that were present in the respective folded building
modules.
15. The house of claim 14 having a structural frame, wherein the
first and second unfolded building module provide the structural
frame of the building.
16. The house of claim 14, wherein the structural frame comprises a
combined structural load carrying member formed from one or more
structural load carrying members of the first unfolded building
module and one or more structural load carrying members of the
second unfolded building module.
17. The house of claim 14, wherein the first unfolded building
module has a section that provides a first interior surface of the
first unfolded building module and a second interior surface of the
second unfolded building module, wherein the first and second
interior surface are opposite sites of the section.
18. The house of claim 14, wherein the connected unfolded building
modules are not connected with a marriage wall.
19. The house of claim 14, wherein the first and second unfolded
building modules, when unconnected, are structurally independent in
folded configuration and not structurally independent in unfolded
configuration.
20. The house of claim 14, wherein the first and second unfolded
building modules in folded configuration are dimensioned and shaped
such that fit within a volume spanned by a length of 70', a width
of 16' and a height of 15', while providing in combination a total
floor area of between 300 and 5000 square feet.
21. The house of claim 14, wherein the first and second unfolded
building modules are connected at one side and positioned such that
they only share part of the side.
22. The house of claim 14, wherein the building has a structural
frame that is provided by up to five connected complementary
unfolded building modules.
23. A method of forming a building comprising: (a) setting a first
folded building module on a foundation, the folded building module
having a core structure and an unfoldable structure attached to the
core structure, the unfoldable structure including a plurality of
foldably connected panels; (b) unfolding part or all of the
unfoldable structure of the first folded building module to form an
unfolded structure; (c) setting a complementary building module on
the foundation and positioned such that panels of the complementary
building module complement respective panels of the unfolded
structure; (d) connecting the panels of the complementary building
module and respective panels of the unfolded structure; and (e)
connecting one or more roof elements to the building modules.
Description
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/388,673, filed Oct. 1, 2010. The entire
teachings of the above application are incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] Foldable houses have been described in the literature;
however, very few have been built. Reasons that have hindered
commercialization of foldable houses include the large extent of
work that needs to be performed at the building site, the presumed
limited design capabilities and difficulty of designing houses that
have sufficiently large and interesting floor plans while having
corresponding compact and easily transportable folded
configurations.
[0003] There is, therefore, a need for foldable houses and
buildings that exhibit more design flexibility, are formed from
easily transported folding building modules, and allow buildings
that are substantially in finished condition.
SUMMARY OF THE INVENTION
[0004] A first embodiment of the present invention is a building
formed at least in part from a first unfolded building module
connected to a complementary building module.
[0005] A second embodiment of the present invention is a house. The
house is formed at least in part from a first unfolded building
module and a connected complementary second unfolded building
module, wherein the first unfolded building module and the second
unfolded building module, each independently, have a core part and
an unfolded part attached to the respective core part; i) the
unfolded part of the first unfolded building module is connected to
a complementary core part of the second unfolded building module,
ii) the unfolded part of the first unfolded building module is
connected to the complementary unfolded part of the second unfolded
building module, or iii) the core part of the first unfolded
building module is connected to a complementary core part of the
second unfolded building module; and the first unfolded building
module and/or the second unfolded building module contain kitchen
elements and/or bathroom elements in one or both of the respective
core structures that were present in the respective folded building
modules.
[0006] A third embodiment of the present invention is a method of
forming a building. The method includes (a) setting a first folded
building module on a foundation, the folded building module having
a core structure and an unfoldable structure attached to the core
structure, the unfoldable structure including a plurality of
foldably connected panels, (b) unfolding part or all of the
unfoldable structure of the first folded building module to form an
unfolded structure, (c) setting a complementary building module on
the foundation and positioned such that panels of the complementary
building module complement respective panels of the unfolded
structure, (d) connecting the panels of the complementary building
module and respective panels of the unfolded structure, and (e)
connecting one or more roof elements to the building modules.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing will be apparent from the following more
particular description of example embodiments of the invention, as
illustrated in the accompanying drawings in which like reference
characters refer to the same parts throughout the different views.
The drawings are not necessarily to scale, emphasis instead being
placed upon illustrating embodiments of the present invention.
[0008] FIG. 1 is a schematic axonometric view of the structural
frame of a house according to an exemplary embodiment of the
present invention, substantially provided by two connected
complementary structural frames of two respective unfolded building
modules.
[0009] FIG. 2 is a perspective view of an exemplary unfolding
sequence according to an embodiment of the present invention
starting from two separate folded structural frames of respective
two separate folded building modules to the structural frame
described in FIG. 1.
[0010] FIG. 3 is a schematic floor plan of a completed house
according to an exemplary embodiment of the present invention,
based on the structural frame of FIG. 1.
[0011] FIG. 4 provides schematic views from four sides of a
completed house according to an exemplary embodiment of the present
invention, based on the structural frame of FIG. 1.
[0012] FIG. 5 is a schematic view of a frame element according to
an exemplary embodiment of the present invention.
[0013] FIG. 6 is a schematic view of a frame element according to
an exemplary embodiment of the present invention.
[0014] FIG. 7 is a schematic view of a frame element according to
an exemplary embodiment of the present invention.
[0015] FIG. 8 is a schematic view of a frame element according to
an exemplary embodiment of the present invention.
[0016] FIG. 9 is a schematic view of a frame element according to
an exemplary embodiment of the present invention.
[0017] FIG. 10 is a schematic cross-sectional view illustrating an
exemplary connection assembly connecting a fixed floor panel of one
building module with a folding floor panel in unfolded
configuration of another complementary unfolded building
module.
[0018] FIG. 11 is a schematic cross-sectional view illustrating an
exemplary connection assembly connecting a fixed back wall panel of
one building module with a removable side wall panel of another
complementary unfolded building module.
[0019] FIG. 12 provides a schematic perspective and plan view
illustrating an exemplary connection assembly connecting a fixed
back wall frame element and a fixed floor frame element of one
building module with a folding floor frame element and side wall
frame element of a complementary unfolded building module.
[0020] FIG. 13 is a schematic cross-sectional view illustrating an
exemplary connection assembly connecting a fixed interior wall
panel and a fixed interior side panel of one building module with
an exterior flip (i.e., folding) wall panel of another
complementary unfolded building module.
[0021] FIG. 14 provides a schematic perspective view illustrating
an exemplary connection assembly of a folding floor frame element
and exterior flip wall frame element of one building module with a
fixed floor frame element, fixed interior wall frame element, and
fixed side wall frame element of a complementary unfolded building
module.
[0022] FIG. 15 is a schematic axonometric view of the structural
frame of a house according to an exemplary embodiment of the
present invention, substantially provided by three connected
complementary structural frames of three respective unfolded
building modules.
[0023] FIG. 16 is a schematic axonometric view of the structural
frame of a house according to an exemplary embodiment of the
present invention, substantially provided by two connected
complementary structural frames of two respective unfolded building
modules.
[0024] FIG. 17 provides schematic views of a house that can be
built with a structural frame such as the one shown in FIG. 15.
[0025] FIG. 18 provides schematic views of a house that can be
built with a structural frame such as the one shown in FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The buildings and, particularly, houses of the present
invention are formed at least in part from an unfolded building
module connected to a complementary building module. The
combination of foldable building technology in conjunction with
complementary design as described herein allows fabrication of
substantially finished houses and buildings that exhibit more
design flexibility, are formed from easily transported building
modules, and require little finishing at the building site. It
further allows to reduce the weight of the structural frame, allows
large spaces with high ceilings extending from one complementary
building module to another, allows single and therefore thin panels
between complementary building modules, and allows overall
reduction of material, labor and transport costs.
[0027] A description of example embodiments of the invention
follows.
[0028] Several houses using the building technology described
herein have been built and are described in the following FIGS. 1
to 16.
[0029] FIG. 1 is a schematic axonometric view of the structural
frame 100 of a house according to an exemplary embodiment of the
present invention. In this embodiment, the structural frame is a
structural steel frame, and is substantially provided by two
connected complementary structural frames of two respective
unfolded building modules. The first unfolded structural frame is
made from a number of frame elements, specifically, a fixed floor
frame element 110 in fixed connection with a fixed back wall frame
element 112, a fixed side wall frame element 114, and a further
fixed side wall frame element 116. Frame element 112 is also in
fixed connection with frame elements 114 and 116. In combination,
the frame elements 110, 112, 114 and 116 form a core structure of
the first unfolded building module. Fixed floor frame element 110
is foldably connected to a folding floor frame element 118, and
fixed side wall frame element 116 is foldably connected to a
folding side wall frame element 120 which itself is foldably
connected to a further folding side wall frame element 122. The
folding floor frame element is further foldably connected to an
exterior flip (i.e., folding) wall frame element 124, which itself
is further foldably connected to another exterior flip (i.e.,
folding) wall frame element 126. Analogously to fixed side wall
frame element 116, fixed side wall frame element 114 can be
connected to foldable side wall frame elements (similar to frame
elements 120 and 122). Alternatively, as is the case here, a
removable side wall frame element 128 can be installed. The
foldably connected frame elements provide the unfolded structure of
the first building module, and any removable frame element can be
installed (i.e. connected) separately to respective adjacent frame
elements. In fully folded configuration the foldably connected
frame elements arrange compactly as shown in step (1) of FIG. 2 and
leave substantially all of the core structure volume available for
other parts to be prefabricated and finished in the core volume. It
is noted that the fully folded structural frame 210 of the first
building module includes two foldable side wall frame elements
(similar to frame elements 120 and 122) connected to fixed side
wall frame element 114. However, except for this difference, the
folded and unfolded configurations associated with the first
structural frame are the same. With respect to FIG. 1,
additionally, in fully folded configuration, the foldable floor
frame element 118 provides a wall of the folded module, which
increases structural stability of the building module in folded
configuration, protects prefabricated and finished parts in the
core volume, and thereby facilitates transportation of the
respective building module.
[0030] The second unfolded structural frame is also made from a
number of frame elements, specifically, a fixed floor frame element
130 in fixed connection with a fixed side wall frame element 132, a
further fixed side wall frame element 134, a fixed back wall frame
element 140, and a further fixed back wall frame element 142. Frame
element 140 is also in fixed connection with frame element 134, and
frame element 142 is also in fixed connection with frame element
132. In combination, the frame elements 130, 132, 134, 140 and 142
form a core structure of the second unfolded building module. Fixed
floor frame element 130 is foldably connected to a folding floor
frame element 144, which in turn is foldable connected to a flip
wall 145. Fixed side wall frame element 132 is foldably connected
to a folding side wall frame element 146 which itself is foldably
connected to a further folding side wall frame element 148. The
fixed back wall frame element 140 and 142 are further foldably
connected with a folding clerestory frame element 150. Side frame
elements 136 and 138 are in fixed connection with respective fixed
side wall frame elements 132 and 134, and are not part of the
structural frame in folded configuration. Analogously to fixed side
wall frame element 132, fixed side wall frame element 134 can be
connected to foldable side wall frame elements (similar to frame
elements 146 and 148). Alternatively, as is the case here, a
removable side wall frame element 152 can be installed. The
foldably connected frame elements provide the unfolded structure of
the second building module, and any removable frame element can be
installed (i.e. connected) separately to respective adjacent frame
elements. In fully folded configuration the foldably connected
frame elements arrange compactly as shown in step (7) of FIG. 2 and
leave substantially all of the core structure volume available for
other parts to be prefabricated and finished in the core volume. It
is noted that the fully folded structural frame 220 of the second
building module includes two foldable side wall frame elements
(similar to frame elements 146 and 148) connected to fixed side
wall frame element 134; however, except for this difference, the
folded and unfolded configurations associated with the second
structural frame are the same. With respect to FIG. 1,
additionally, in fully folded configuration, the foldable floor
frame element 144 provides an exterior wall of the folded building
module and the foldable clerestory frame element 150 provides a
further exterior wall of the folded building module, which
increases structural stability of the building module in folded
configuration, protects prefabricated and finished parts in the
core volume, and thereby facilitates transportation of the
respective building module.
[0031] As described above, FIG. 1 shows the structural frame of a
house made from two complementary structural frames, a first
unfolded structural frame and a second unfolded structural frame.
Although only frame elements and respective structural load
carrying members are shown it is to be understood that typically
the house is not only formed from two complementary folded
structural frames, but from two folded building modules that when
unfolded complement each other and form a substantially finished
house including even kitchen elements including but not limited to
cabinets, appliances, and sink(s), and/or bathroom elements
including but not limited to cabinets, shower, bathtub, toilet, and
sink.
[0032] As described above, the structural frame shown in FIG. 1 is
made from a number of frame elements. Exemplary connection
assemblies are also indicated in 151-164, 170 and 180.
[0033] FIG. 2 is a perspective view of an exemplary unfolding
sequence according to an embodiment of the present invention
starting from two separate folded structural frames of respective
two separate folded building modules to the structural frame
described in FIG. 1. For ease of visualization, only the structural
frames are shown and not the complete building modules, however,
the respective building modules include the structural frames and,
thus, the unfolding sequence is the same for the structural frame
and the respective building module. A first folded structural frame
of 210 of a first folded building module is unfolded to form an
unfolded structural frame 215 of the unfolded building module.
Firstly, as shown in (1), the first folded structural frame 210 is
set on a foundation (not shown). Then, the folding floor frame
element 118 folds down to the configuration shown in (2). In the
next step, the exterior flip wall frame element 124 folds up to the
configuration shown in (3). In a further step, a further exterior
flip wall 126 folds up to the configuration shown in (4). Then, the
accordion walls 218 and 219 fold out as shown in (5) to yield the
unfolded structural frame 215. The unfolded structural frame 215
and corresponding unfolded building module exhibit an opening 216,
here on the front side of the unfolded structure of the unfolded
structural frame 215. Accordion wall 218 is made from two folding
side walls, as described above as alternative for the removable
side wall 128 in FIG. 1. Accordion wall 219 is made from folding
side walls 120 and 122 (shown in FIG. 1). Subsequently, a second
complementary folded structural frame 220 is set on the foundation
and connected to the first unfolded structural frame 215 and
corresponding building module. The second building module and
structural frame 220 are adapted to complement the first building
module and structural frame 215. Specifically, in this embodiment,
the interior wall frame element 142 and part of the folding
clerestory frame element 150 of the second structural frame 220
complement the front side of the first unfolded structural frame
215 by providing interior wall frame elements for the first
unfolded structural frame 215. Here, the opening 216 is reduced in
area by fixed interior wall frame element 142. In the context of
the unfolding of folded building modules, the second building
module having the second structural frame, typically, includes
substantially finished panels corresponding to the frame elements,
and panels corresponding to frame elements such as 142 can have
interior finishing material on both sides. After the second
complementary folded building module is set (only structural frame
220 is shown), the folding floor frame element 144 folds down to
the configuration shown in (8). Then, the flip wall frame element
145 folds up to the configuration shown in (9). Then, the accordion
walls 225 and 230 fold out as shown in (10) to the configuration
shown in (11). Accordion wall 225 is made from two folding side
walls, as described above as alternative for the removable side
wall 152 in FIG. 1. Accordion wall 219 is made from folding side
walls 146 and 148 (shown in FIG. 1). Finally, the folding
clerestory frame element 150 is folded up to yield the structural
frame 200 of a house according to an exemplary embodiment of the
present invention. Likewise, the unfolding of the corresponding
building modules that include the first and second structural
frames, results in part of a house, and, at this stage, further
elements such as some interior walls and/or roof elements are
connected to the structural frame to form the completed house.
Typically, kitchen and bathroom elements are already included in
the folded building modules.
[0034] FIG. 3 is a schematic floor plan 300 of a completed house
according to an exemplary embodiment of the present invention,
based on the structural frame 100 of FIG. 1. The house is formed in
part from two complementary unfolded building modules that are the
basis for the completed respective parts 210 and 220 of the house.
Substantial parts of the plumbing, heating, cooling and electrical
system (not shown) can be installed in the core structure of the
building modules. This includes kitchen elements such as 322 and
bath elements such as 324. Interior walls such as 326 can be
foldably attached to the structural frames of the building modules,
or they are separate and are connected to the structural frame at
the building site. Typically, the structural frame can be adapted
for attachment of these interior walls. The house includes several
rooms, including a kitchen area 330, a first bathroom 335, a first
bedroom 340, a second bathroom 345, a second bedroom 350, an office
room 355 and a living room 357. The house features a plurality of
windows 360, which typically are included in the folded building
modules.
[0035] FIG. 4 provides schematic views from four sides (a), (b),
(c) and (d) of a completed house according to an exemplary
embodiment of the present invention. The house is based on the
structural frame of FIG. 1, and can have the floor plan shown in
FIG. 3. The house has two parts 310 and 320. Part 210 is
substantially provided by an unfolded building module having the
unfolded structural frame 215 (see FIG. 2) and part 210 is
substantially provided by an unfolded building module having the
unfolded structural frame 235 (see FIG. 2). The views further show
the roof elements 410 and 420.
[0036] FIG. 5 is a schematic view of an exemplary fixed back wall
frame element 140 in FIG. 1 with exemplary dimensions. It can, for
example, be made from four structural steel load carrying members
that have the following exemplary dimensional characteristics:
TABLE-US-00001 Member Tag Length 510 C 6 .times. 13 12' 520 W 4.125
.times. 13 12' 2'' 530 W 6.25 .times. 16 8' 9'' 7/8 540 HSS 4
.times. 2 .times. 0.25 8' 9'' 7/8
[0037] In the "Tag" column of the Table above and the ones below, W
stands for "W-Section" or a "Wide Flange" member, C for a
"C-Channel", and HSS for "Hollow Structural Steel Member". For Cs
and Ws, the first number is the depth of the member and the second
number is the weight per lineal foot. So, in the case of "C
6.times.13", it is a C-channel member with a depth of 6'' and a
weight of 13 pounds/ft.
[0038] FIG. 6 is a schematic view of an exemplary interior wall
frame element 142 in FIG. 1 with exemplary dimensions. It can, for
example, be made from four structural steel load carrying members
that have the following exemplary dimensional characteristics
TABLE-US-00002 Member Tag Length 610 PLATE 4 .times. 0.25 12' 2''
620 W 4.125 .times. 13 12' 2'' 630 HSS 4 .times. 2 .times. 0.25 8'
9'' 5/8 640 W 6.25 .times. 16 8' 9'' 5/8
[0039] FIG. 7 is a schematic view of an exemplary clerestory frame
element 150 in FIG. 1 with exemplary dimensions. It can, for
example, be made from twelve structural steel load carrying members
that have the following exemplary dimensional characteristics:
TABLE-US-00003 Member Tag Length 701 C 6 .times. 10.5 23' 10' 702 W
6.25 .times. 16 48' 703 HSS 2 .times. 4 .times. 0.25 12' 2'' 704 W
4 .times. 13 11' 5'' 3/4 705 HSS 2 .times. 4 .times. 0.25 12' 2''
706 HSS 4 .times. 2 .times. 0.25 6' 2'' 1/4 707 W 6 .times. 16 6'
2'' 1/4 708 W 6 .times. 16 6' 2'' 1/4 709 HSS 4 .times. 2 .times.
0.25 6' 2'' 1/4 710 W 4 .times. 13 2' 2'' 3/4 711 W 4 .times. 13 2'
2'' 3/4 712 W 4 .times. 13 2' 2'' 3/4
[0040] FIG. 8 is a schematic view of an exemplary exterior flip
(i.e., folding) wall frame element 124 in FIG. 1 with exemplary
dimensions. It can, for example, be made from four structural steel
load carrying members that have the following exemplary dimensional
characteristics:
TABLE-US-00004 Member Tag Length 810 C 6 .times. 13 12' 820 W 4.125
.times. 13 12' 830 HSS 4 .times. 2 .times. 0.25 8' 9'' 7/8 840 HSS
4 .times. 2 .times. 0.25 8' 9'' 7/8
[0041] FIG. 9 is a schematic view of an exemplary exterior flip
(i.e., folding) wall frame element 126 in FIG. 1 with exemplary
dimensions. It can, for example, be made from four structural steel
load carrying members that have the following exemplary dimensional
characteristics:
TABLE-US-00005 Member Tag Length 910 HSS 2 .times. 4 .times. 0.25
12' 920 W 6.25 .times. 16 12' 930 HSS 4 .times. 2 .times. 0.25 3'
5'' 1/4 940 HSS 4 .times. 2 .times. 0.25 3' 5'' 1/4
[0042] FIG. 10 is a schematic cross-sectional view illustrating an
exemplary connection assembly 1000 connecting a fixed floor panel
1010 (based on the fixed floor frame element 130 of FIG. 1) of one
building module with a folding floor panel (in unfolded
configuration and based on the folding floor frame element 118 of
FIG. 1) of another complementary unfolded building module.
Cross-sectional view (a) of FIG. 10 shows the panels 1010 and 1020
in connected and finished configuration. Cross-sectional view (b)
of FIG. 10 shows the cross-sectional outlines 1011 and 1012 of
respective panels 1010 and 1020. Cross-sectional view (c) of FIG.
10 shows how the two panels are connected with suitable fasteners
1070 (e.g., HILTI Kwik-Flex screws) by fastening the steel plate
1042 of panel 1020 with the C-channel 1035 of panel 1010, and by
fastening the steel plate 1040 of panel 1010 with the C-channel
1037 of panel 1020. Panels 1010 and 1020 are substantially in
finished condition, however, to allow fastening the C-channels, a
section 1031 above the C-channels is unfinished (or the part 1031
can be included in the folded building module, and disassembled
before the respective panel is moved into unfolded configuration)
to allow access to the channels for fastening purposes (as shown in
view (b) of FIG. 10). After, the panels 1010 and 1020 are
connected, the unfinished area 1031 can be finished with finishing
material (e.g., flooring) 1030 (or, the part 1031 can be returned
into position). Each panel includes blocking members 1055 connected
to the interior surface areas of the respective C-channels, and
further blocking members 1050 connected to the respective blocking
members 1055. The blocking members are adapted to facilitate
connection of subflooring 1060 (e.g., plywood, oriented strand
board, or other pre-finish surfacing) and finish floor 1065 to the
frame element. As illustrated in FIG. 10 the structural load
carrying members, C-channels 1035 and 1037, of the two panels
complement each other to form a combined structural load carrying
member of approximately I-beam shape indicated in FIG. 1 as element
153. Additionally, the panels 1010 and 1020 complement each other
to form a continuous floor area from one unfolded building module
to the connected unfolded building module.
[0043] FIG. 11 is a schematic cross-sectional view illustrating an
exemplary connection assembly 1100 connecting a fixed back wall
panel 1120 (based on the fixed back wall frame element 140 of FIG.
1) of one building module with a removable side wall panel 1110
(based on the removable side wall frame element 128 of FIG. 1) of
another complementary unfolded building module. FIG. 11 shows the
panel 1110 and 1120 in connected and finished configuration. Panel
1110 includes a hollow structural steel member 1114, a blocking
member 1112 fastened to the member 1114, and interior wall board
(e.g., gypsum board) 1116 and sheathing 1118 (e.g., plywood,
oriented strand board, etc.). Panel 1120 includes a steel I-beam
member 1124, a blocking member 1122 fastened to the member 1124,
and interior wall board 1126 and sheathing 1128 fastened to the
blocking member. After the panels 1120 and 1124 are fastened to
each other, a further blocking member 1122 and interior wall board
1123 are used to finish the connection assembly. As illustrated in
FIG. 11 the structural load carrying members, I-beam 1124 and 1114,
of the two panels complement each other to form a combined
structural load carrying member indicated in FIG. 1 as element 163.
Additionally, the panels 1110 and 1120 complement each other to
form a continuously finished wall through the connection corner
1150.
[0044] FIG. 12 provides a schematic perspective (a) and plan view
(b) illustrating an exemplary connection assembly 1200 similar to
170 in FIG. 1 of structural load carrying members 1210 of a fixed
back wall frame element (only shown in part) and structural load
carrying members 1220 of a fixed floor frame element (only shown in
part) of one complementary building module with structural load
carrying members 1230 of a side wall frame element (only shown in
part) and structural load carrying members 1240 of a folding floor
frame element (only shown in part) of another complementary
unfolded building module. The bolt holes 1250 can be drilled on
site to ensure alignment and the structural load carrying members
bolted with bolts (not shown).
[0045] FIG. 13 is a schematic cross-sectional view illustrating an
exemplary connection assembly 1300 connecting a fixed interior wall
panel 1301 (based on the fixed interior wall frame element 142 of
FIG. 1) and a fixed interior side panel 1302 (based on the fixed
side wall frame element 132 of FIG. 1) of one building module with
an exterior flip (i.e., folding) wall panel 1303 (based on the
exterior flip (i.e., folding) wall frame element 124 of FIG. 1) of
another complementary unfolded building module. FIG. 13 shows the
panels 1301, 1302 and 1303 in connected and finished configuration
except for one area which is adapted to receive a non-structural
interior wall panel 1304 which includes blocking members 1385 and
interior wall board 1380. Panel 1303 includes a hollow structural
steel member 1305, a blocking member 1310 fastened to the member
1305, and sheathing 1315 and interior wall board 1320 fastened to
the blocking member 1310. Panel 1302 includes a steel I-beam member
1325, a blocking member 1330 fastened to the member 1325, a
blocking member 1335 fastended to the member 1325, and sheathing
1340 and interior wall board 1345 fastened to the blocking members.
Panel 1301 includes a hollow structural steel member 1350, a
blocking member 1355 fastened to the member 1350, two blocking
members 1360 and 1365 fastened to the blocking member 1355, and
interior wall board 1370 and interior wall board 1375 fastened to
the blocking members. The folded up exterior flip wall panel 1303
of the first building module is complementary to the fixed panels
1301 and 1302 of the second building module. The structural load
carrying members, I-beam 1325, hollow structural steel sections
1360 and 1305 of the three panels complement each other to form a
combined structural load carrying member (also, indicated in FIG. 1
as element 164), and the three panels upon connection provide
continuous finishing through the connection corners 1390.
[0046] FIG. 14 provides a schematic perspective view illustrating
an exemplary connection assembly 1300 similar to 180 in FIG. 1 of
structural load carrying members 1310 of a folding floor frame
element and structural load carrying members 1320 of an exterior
flip wall frame element of one building module with structural load
carrying members 1330 of a fixed floor frame element, fixed
interior wall frame element (not shown), and structural load
carrying members 1340 of a fixed side wall frame element of a
complementary unfolded building module.
[0047] FIG. 15 is a schematic axonometric view of the structural
frame 1500 of a house according to an exemplary embodiment of the
present invention, substantially provided by three connected
complementary structural frames 1510, 1520 and 1530 of three
respective unfolded building.
[0048] FIG. 16 is a schematic axonometric view of the structural
frame of a house 1600 according to an exemplary embodiment of the
present invention, substantially provided by two connected
complementary structural frames 1610 and 1620 of two respective
unfolded building modules.
[0049] FIG. 17 provides schematic views of a house that can be
built with a structural frame such as the one shown in FIG. 15.
FIG. 17 provides a front view (a) showing three connected
complementary building modules 1710, 1720 and 1730, a back view
(b), a view on the outside of a unfolded building module 1710 (c),
a back view on the outside unfolded building module 1730 (d), a
view from inbetween module 1710 and 1730 on module 1710 (e), and a
view from inbetween module 1710 and 1730 on module 1730 (e).
[0050] FIG. 18 provides schematic views of a house that can be
built with a structural frame such as the one shown in FIG. 16.
FIG. 18 provides a back view (a) showing two connected
complementary building modules 1810 and 1820, a front view (b), a
first side view (c) and a second side view (c).
[0051] Building modules of the present invention can be formed from
fixed panels and folding panels that are foldably connected to
other folding panels or fixed panels. Accordingly, building modules
can include folding panels or are entirely formed from fixed
panels. Typically, the building modules include folding panels in
an arrangement that allows the building modules to be folded into a
folded configuration (typically, of box shape) that takes up a
smaller volume, primarily, for transport purposes. Such a folding
building module can be unfolded to result in an unfolded building
module.
[0052] The panels that can form an unfolded building module have
frame elements (see, e.g. FIGS. 5-9) which typically are made from
a number of structural load carrying members in fixed connection.
The structural load carrying members of different panels can be
connected to provide a fixed connection of the panels in both
folded and unfolded configuration of the folding building module,
or can be foldably connected to provide a foldable connection of
the panels and thereby allow folding and unfolding of the folding
building module. After unfolding and affixing of the frame elements
of the panels through connection of respective structural load
carrying members, the frame elements form at least part of the
structural frame of building or house.
[0053] The buildings (typically, houses) of the present invention
are formed at least in part from a first unfolded building module
connected to a complementary building module. The complementary
building module can be a folding building module, but can also be a
fixed building module, that is, a building module that does not
have a structure that can be unfolded. Typically, buildings, and
particularly, houses are formed at least in part from a first
unfolded building module connected to a complementary second
unfolded building module.
[0054] The complementary building modules of the present invention
are not merely building modules that can be placed structurally
independently side by side, stacked, or otherwise positioned next
to the each other, but are adapted to complement each other.
Typically, this is achieved without substantial structural
redundancy. In comparison, when conventional building modules are
connected, substantial structural redundancy results, for example,
a marriage wall for building modules placed side by side, or a
ceiling of a first building module connected to the floor of a
second building module stacked on top of the first building module.
As a contrasting example, the complementary building module of the
present invention can include a panel having a first side and an
opposing second side, and the first side provides an interior
surface in the complementary building module and the second side
provides and interior surface in the connected first unfolded
building module.
[0055] The unfolded building module and the complementary building
module typically are connected through structural load carrying
members. Typically, these members are dimensioned and shaped to
form a combined structural load carrying member, which has a load
carrying capacity suitable for the part of the structural frame of
the building that it provides. Connecting structural load carrying
members in connection assemblies such as illustrated in FIGS. 10-14
minimizes structural redundancy. Further, typically, the structural
load carrying members considered separately (unconnected) do not
have a load carrying capacity suitable for the part of the
structural frame of the building that it provides. More generally,
typically, the complementary building modules are structurally
interdependent.
[0056] The complementary folding building modules of the present
invention can further be dimensioned and shaped to fold compactly
and/or arrange compactly with other folded building modules.
[0057] The buildings of the present invention can be formed, in
part or substantially completely, from a plurality of complementary
unfolding building modules. The number of complementary unfolding
building modules that can be connected to form the buildings of the
present invention is not limited in principal; however, typically,
the buildings include up to one hundred complementary unfolding
building modules, more typically, up to ten, even more typically,
two or three complementary unfolding building modules.
[0058] The folding building modules of the present invention can
have a core part and an unfolded part connected to the core part.
Typically, (i) the unfolded part (or structure) of a first unfolded
building module is connected to a complementary core part (or
structure) of a second unfolded building module or to a fixed
building module, or (ii) the core part (or structure) of a first
unfolded building module is connected to a complementary core part
(or structure) of the second unfolded building module or a fixed
building module.
[0059] Buildings of the present invention can further include
non-complementary building modules and parts (such as
non-structural removable walls, non-structural interior walls,
etc.) that can be affixed to the parts of the buildings that are
formed from connected complementary building modules (particularly,
complementary unfolded building modules).
[0060] The complementary building modules of the present invention
can be prefabricated such that the buildings, after unfolding on
the building site and connecting of removable sections (such as
roof elements and non-structural interior walls), are substantially
in finished condition. That is, they do not typically require or at
least significantly reduce the addition of interior and exterior
finish materials with the exception of minor, non-structural
finishing in areas required for folding movement. Further,
typically, the houses of the present invention include roof
sections that are panelized but can be easily installed at the
building site. The prefabrication process can be reduced
substantially, even to the extent that merely complementary folding
structural frames of the present invention are prefabricated and
unfolded and connected at the building site.
[0061] Further, all necessary mechanical and electrical systems for
the residential or commercial foldable building, for example, all
the required appliances and plumbing fixtures, can be installed in
a core part (or structure) (i.e., a part of the structural frame of
the foldable building that is made of frame elements that are not
unfolded at the building site). Flexible piping and wiring can also
be chased throughout both fixed and foldably connected panels of
the foldable building units of the present invention.
[0062] Use of structural steel in the form of appropriately
dimensioned I-beams, c-channels, wide-flange beams, and hollow
structural sections allows for large frame geometries as part of
the structural frame of the foldable building unit, for example,
rectangular frame elements spanning the entire side of a foldable
building, reducing prefabrication cost and/or simplifying unfolding
at the building site.
[0063] Further, foldable structural frames substantially made of
metal frame elements (e.g., made from hot-formed steel such as
I-beams, c-channels, wide-flange beams, and hollow structural
sections) can be prefabricated to superior tolerances such that a
respective folding building module in substantially finished
condition upon unfolding exhibits reduced or no gaps in the seam
areas between foldably connected frame elements thereby reducing
the work associated with on-site finishing of these seam areas.
[0064] The buildings of the present invention, for example, the
building corresponding to the structural frame shown in FIG. 1 can
further include a number of prefabricated interior walls (e.g, as
shown in FIG. 3) that can be fixed, foldably connected, or
panelized and form one or more rooms in the unfolded building.
[0065] The buildings of the present invention can be several
stories high.
[0066] Steel frame elements of the present invention are typically
combined with wooden or light-gauge metal intermediate elements to
form lightweight steel and wood/light-gauge metal hybrid structures
in which the frame elements provide structural stability and the
wooden or light-gauge metal intermediate elements provide
substantial lateral structural resistance and/or are used to attach
interior and exterior finishing material using standard
construction approaches, reducing labor training and associated
costs.
[0067] In certain embodiments of the present invention, structural
load carrying members connecting different frame elements of the
structural frame allow blocking material (e.g. wood or light-gauge
metal studs) to be connected to inside areas of the structural load
carrying members, and the structural load carrying members are
positioned such that the blocking members face the outside of the
foldable building unit. This allows structural frames that have a
continuous conventional structural grid (e.g., 16 inch wood lumber
grid) through the edges/corners of the folding building module,
thereby allowing attachment of exterior finishing material through
the edges/corners using standard construction approaches, reducing
labor training and associated costs, and work at the building
site.
[0068] Use of these strong and lightweight structures can also
substantially reduce the amount of required building material and
the weight of the frame elements, which in turn facilitates the
transport of larger folded building modules for a given maximal
allowed weight according to given road regulations.
[0069] Indirect connections of interior and/or exterior finishing
materials to metal frame elements (particularly, frame elements
made of structural steel sections) are one aspect of a
"multi-tolerance" building approach that disaggregates and cushions
brittle or otherwise fragile finish materials from the vibrational,
kinetic and settling forces applied to the structural frame during
shipping, setting, unfolding and settling of the prefabricated
foldable building units. A second aspect of a multi-tolerance
building approach is provided by using offset hinges (in
particular, L-shaped offset hinges) which are specifically
engineered to safely nest hingedly (i.e., foldably connected with
one or more hinges) connected frame elements at a designed distance
away from its neighboring frame element, allowing, for example, for
thicker wall depths and thus the prefabricated inclusion of finish
materials. This is associated with a significant reduction in the
scope of work to be completed on-site, where costs and scheduling
are far less manageable. Thus, foldable building units of the
present invention can include final interior finishing, such as
trim, gypsum board, paint or wallpaper.
[0070] Structural load carrying members of the present invention
can be foldably connected with hinges to foldably connect frame
elements and respective panels. More typically, structural load
carrying members of the present invention can be foldably connected
with offset hinges, and preferably, L-shaped offset hinges adapted
and positioned to remain within the building envelope. In
completely folded configuration of foldably connected panels,
L-shaped offset hinges provide an offset, which allows sufficient
clearance for finish and other materials. Further, the interior
finish materials attached to the frame elements can be sufficiently
offset from each other to avoid direct and potentially damaging
contact, for example, during transport.
[0071] A folding building module in "unfolded configuration" is a
foldable building unit in which the foldably connected frame
elements have been unfolded into positions that can be maintained
in the finished condition of the resulting building. A folding
building module in "folded configuration" is a folding building
module in which foldably connected frame elements are folded into
positions suitable for uploading, transport, and/or unloading of
the building unit.
[0072] A "structural frame" as used herein, refers to the totality
of structural load carrying members of a building module or
building that are primarily responsible for providing structural
stability of the building module or building by transmitting loads
(e.g., static, dynamic, and/or vibrational loads) to the ground.
Structural frames can include members that are made of a plurality
of materials in various forms and dimensions. Suitable materials
that can be used include but are not limited to metal (e.g.,
aluminum or steel), wood and polymers. Typically, steel is
used.
[0073] Suitable structural load carrying members include but are
not limited to hollow structural sections, C-channels (with or
without return), I-beams (including S and W type), T-beams, angle
beams, and wide-flange beams. For example, the structural load
carrying members can be commercially available American standard
structural load carrying members. The selection of a material, form
and dimension for a given structural part or member of a structural
frame is interdependent and depends on factors such as the position
of the structural part or member in the structural frame, and
whether the member is part of a frame element that is foldably
connected.
[0074] In the context of the shape of structural load carrying
member, "inside", "inside area", "interior area", "inside surface"
or "interior surface" refers to the areas of the structural load
carrying member that are inside of a box enveloping the structural
load carrying member. That is, if a cross-sectional view of the
structural load carrying member is considered any part of the
perimeter of the structural load carrying member that is inside of
a rectangle enveloping (i.e., with minimum perimeter length of the
rectangle) the structural load carrying member corresponds to the
"inside", an "inside area", an "interior area", an "inside surface"
or an "interior surface."
[0075] Interior and exterior finish materials can be attached to
the structural frame, typically, by attachment with intermediate
elements affixed to frame elements of the structural frame.
Interior and exterior finishing materials are typically attached
(e.g., glued, nailed, screwed, welded and/or bolted, or otherwise
affixed) to intermediate elements. Interior finish materials
include but are not limited to wall finishing (for example, gypsum
board), ceiling finishing and floor finishing (for example,
sheathing with Bamboo flooring on top). Exterior finishing elements
include but are not limited to siding and roofing.
[0076] For finish materials, and, in particular, interior finish
materials, it has been found that "indirect connection" to the
frame elements to reduce contact, partially or entirely, of the
interior finish materials with the frame elements is advantageous
for one or more of the following reasons. Reduced contact can (a)
reduce the transfer of structural stresses from one or more frame
elements of the structural frame to the often fragile and brittle
interior finish materials thereby reducing or eliminating
significant damage (such as dry wall cracking) of the interior
finish materials, in particular, during folding, uploading,
transporting, unloading and/or unfolding of the foldable building
unit, and settling, (b) reduce or eliminate the exposure of the
interior finish materials to water, for example, water that can
condensate on metal parts of the frame elements, and (c) reduce
heat transfer between the inside of the finished building unit to
the outside of the finished building unit.
[0077] Thus, generally, it is preferred to use indirect rather than
direct connections of finish materials, particularly, interior
finish materials with respective frame elements. However, even
though indirect connections are typically preferred, not all
connections between interior finish material and a respective frame
element have to be indirect.
[0078] Typically, intermediate elements are made, at least in part,
of materials that have a force cushioning effect, that is, force
cushioning elements such as, for example, wood, sprayed foam, and
light-gauge metal studs. Typically, an intermediate element is
positioned and dimensioned such that it can connect or can be
connected (e.g., using powder-actuated fasteners or self-tapping
screws) to the frame element through one area of the intermediate
element (e.g., through one side of the intermediate element) and
that it can be connected to the finish material, particularly, the
interior finish material (for example, using nails or screws)
through another area of the intermediate element (e.g., through
another side of the intermediate element). Even more preferably,
intermediate elements are entirely made of force cushioning
materials such as wood.
[0079] Folding building modules of the present invention typically
include wall panels and floor sections that are in substantially
finished condition, that is, with the exception of unfinished areas
dimensioned to accommodate folding of the frame elements, and
unfinished areas due to wall connection seams (i.e., seams between
walls that are not connected but upon unfolding jointly form a
wall), these wall panels, roof and floor panels are finished.
[0080] A building or house or part of a building or house that is
substantially in finished condition after connection of two or more
complementary modules of this invention is a building, house or
part thereof in which more than 75%, preferably 85%, and more
preferably 90% of the construction of the building, house or part
thereof is completed upon connection of the complementary modules.
Thus, the complementary building modules (unfolded and/or fixed)
can connect to form part of a building or house which is in
substantially finished condition upon connection of the modules. If
substantially all of the building is made from complementary
building modules, the entire building can be in substantially
finished condition once the complementary building modules are
connected. Examples of when a part of a building or an entire
building is "substantially finished", is when the interior surfaces
of the part are substantially finished with finish material, such
as a finish floor (e.g., tiles, hardwood floor, laminate, etc.),
finish wall (e.g., wall board, wall paper, etc.), electrical
elements (e.g., switches, lamps, electrical wiring, electrical
panel, etc.), and heating and cooling elements (e.g., heating
system, cooling system, duct work, etc.); typically, this even
includes kitchen elements including but not limited to cabinets,
appliances and sink(s), and/or bathroom elements including but not
limited to cabinets, shower, bathtub, toilet and sink. However, the
substantially finished building, house or part thereof typically
includes some unfinished elements upon connection of the
complementary building modules, for example, wall connection seams
(i.e., seams between walls that are not connected but upon
unfolding jointly form a wall), areas in connection assemblies
intended for connection of removable substantially finished panels
(e.g., the area in FIG. 13 to which panel 1304 will be
connected).
[0081] "Finished panels" as referred to herein, are panels that
include frame elements and interior finish materials connected
(typically, indirectly) to them, and can also include elements such
as doors and windows.
[0082] The folded building modules of the present invention are
typically dimensioned such that transport with a transport vehicle
is possible, preferably, with a semitrailer and without requiring a
special transport permit. Regulations pertaining to the operation
of trucks and trailers vary from country to country, and, in some
instances from state to state.
[0083] Further, the folded building modules of the present
invention can include a folding floor panel which provides a wall
of the folded building module, which increases stability of the
building module in folded configuration, protects prefabricated and
finished parts in the core volume, and thereby facilitates
transportation of the building module.
[0084] A fourth embodiment of the present invention is a building
built in a process including the following steps: (a) setting a
first folded building module on a foundation, the folded building
module having a core structure and an unfoldable structure attached
to the core structure, the unfoldable structure including a
plurality of foldably connected panels; (b) unfolding part or all
of the unfoldable structure of the first folded building module to
form an unfolded structure; (c) setting a complementary building
module on the foundation and positioned such that panels of the
complementary building module complement respective panels of the
unfolded structure; (d) connecting the panels of the complementary
building module and respective panels of the unfolded structure;
and (e) connecting one or more roof elements to the building
modules.
[0085] A fifth embodiment of the present invention is a building
comprising a first unfolded building module connected to a
complementary building module.
[0086] A sixth embodiment of the present invention is a house
comprising a first unfolded building module connected to a
complementary second unfolded building module, wherein the first
unfolded building module and the second unfolded building module,
each independently, have a core part and an unfolded part attached
to the respective core part; i) the core part of the first unfolded
building module is connected to a complementary unfolded part of
the second unfolded building module, or ii) the core part of the
first unfolded building module is connected to a complementary core
part of the second unfolded building module; and the first unfolded
building module and/or the second unfolded building module
contained kitchen elements and/or bathroom elements in one or both
of the respective core structures that were present in the
respective folded building module.
[0087] A first specific embodiment is a building or house as
described in the first, second, fourth, fifth or sixth embodiment
of the present invention, wherein the first unfolded building
module includes a structural load carrying member through which the
unfolded building module is connected to a structural load carrying
member of the complementary building module without substantial
structural redundancy.
[0088] More particularly, the structural load carrying member of
the first unfolded building module can form part of a first panel
and the structural load carrying member of the first unfolded
building module can form part of a second panel, and the first
panel and second panel upon fastening of the structural load
carrying members in a connection area provide substantially
finished exterior and/or interior surfaces continuously throughout
the connection area with the exception of an area for the fastening
of the structural load carrying members.
[0089] A second specific embodiment is a building or house as
described in the first, second, fourth, fifth or sixth embodiment,
wherein the complementary building module is a second unfolded
building module.
[0090] A third specific embodiment is a building or house as
described in the first, second, fourth, fifth or sixth embodiment,
wherein the complementary building module includes a panel having a
first side and an opposing second side, and the first side provides
an interior surface in the complementary building module and the
second side provides and interior surface in the first unfolded
building module.
[0091] A fourth specific embodiment is a building or house as
described in the first, second, fourth, fifth or sixth embodiment
having a steel structural frame, wherein a plurality of connected
complementary unfolded building modules provides more than 50% of
the steel structural frame of the building.
[0092] More particularly, the plurality of connected complementary
unfolded building modules provides more than 75% of the steel
structural frame of the building.
[0093] Even more particularly, the plurality of connected
complementary unfolded building modules provides more than 90% of
the steel structural frame of the building.
[0094] Yet even more particularly, the plurality of connected
complementary unfolded building modules provides substantially all
of the steel structural frame of the building.
[0095] In a fifth specific embodiment, the first unfolded building
module of the first, second, fourth, fifth or sixth embodiment has
a core part and an unfolded part connected to the core part.
[0096] Particularly, the complementary building module is a second
unfolded building module, and (i) the unfolded part of the first
unfolded building module is connected to a complementary core part
of the second unfolded building modules, or (ii) the core part of
the first unfolded building module is connected to a complementary
core part of the second unfolded building modules.
[0097] A sixth specific embodiment is a building or house as
described in the first, second, fourth, fifth or sixth embodiment
of the present invention, wherein the first unfolded building
module and the complementary building module are connected at one
side and positioned to share only part of the side.
[0098] A seventh specific embodiment is a building or house as
described in the first, second, fourth, fifth or sixth embodiment
of the present invention, wherein the first unfolded building
module and the complementary building module are connected through
a plurality of connection assemblies that (i) form from
complementary panels of the building modules, and (ii) are in
substantially finished condition when the panels are connected.
[0099] An eighths specific embodiment is a building or house as
described in any of the preceding embodiments, wherein the first
unfolded building module and the complementary building module are
structurally interdependent.
[0100] A ninth specific embodiment is a building or house as
described in any of the preceding embodiments, wherein the first
unfolded building module and the complementary building module are
connected without substantial structural redundancy.
[0101] A tenth specific embodiment is a building or house as
described in any of the preceding embodiments, wherein the first
unfolded building module and the complementary building module of
are not independently structurally stable when not connected to
each other.
[0102] An 11.sup.th specific embodiment is a building or house as
described in any of the preceding embodiments comprising a combined
structural load carrying member formed from one or more structural
load carrying members of the first unfolded building module and one
or more structural load carrying members of the second unfolded
building module.
[0103] A 12.sup.th specific embodiment is a building or house as
described in any of the preceding embodiments, wherein the first
and second unfolded building modules in folded configuration are
dimensioned and shaped such that they fit within a volume spanned
by a length of 70', a width of 16' and a height of 15', while
providing in combination a total floor area of between 300 and 5000
square feet. Particularly, a total floor are of between 300 and
3000 square feet is provided.
[0104] A 13.sup.th specific embodiment of the present invention is
a building or house formed by the method as described in the third
embodiment.
[0105] A 14.sup.th specific embodiment of the present invention is
a method for forming a building as described in the third
embodiment, wherein the panels of the complementary building module
and respective panels of the unfolded structure are connected
without substantial structural redundancy.
[0106] In a more particular embodiment, the method further
comprises setting and connecting further complementary building
modules to the first and/or complementary building module.
[0107] Further teaching of the general folding building technology
relevant to the present invention is described in International
Patent Application No. PCT/US2010/050041, filed Sep. 23, 2010, and
published as WO2011/038145, and in International Patent Application
No. PCT/US2011/029643, filed Mar. 23, 2011.
[0108] The relevant teachings of these patent applications, and all
patents, published applications and references cited herein are
incorporated by reference in their entirety.
[0109] While this invention has been particularly shown and
described with references to example embodiments thereof, it will
be understood by those skilled in the art that various changes in
form and details may be made therein without departing from the
scope of the invention encompassed by the appended claims.
* * * * *