Foldable building units are provided based on structural frame and connection assembly designs that enable greater construction efficiency and flexibility. The structural frame and connection assembly designs allow for easier connection of frame elements in the prefabrication process of the foldable
Foldable building units are provided based on structural frame and connection assembly designs that enable greater construction efficiency and flexibility. The structural frame and connection assembly designs allow for easier connection of frame elements in the prefabrication process of the foldable building units and for easier connection of frame elements at the building site, for example, of foldably connected frame elements after unfolding. They also allow for more finish in the prefabrication process, and/or less and faster work at the building site, for example, by enabling conventional structural lumber grids that can be continuous through the edges and corners of the building envelope for conventional exterior finishing, while providing a tight building envelope with reduced heat transfer, particularly, through the edges of the foldable building unit.
대표청구항▼
1. A foldable building unit, comprising (a) a first frame element having a first structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, a metal angle beam, and a metal wide-flange beam;(b) a second fram
1. A foldable building unit, comprising (a) a first frame element having a first structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, a metal angle beam, and a metal wide-flange beam;(b) a second frame element having a second structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, and a metal wide-flange beam; provided that the first structural load carrying member and the second structural load carrying member are not both hollow structural metal sections; and (i) the first structural load carrying member and the second structural load carrying member are lengthwise connected to form a fixed connection between the first frame element and the second frame element, or (ii) the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected to allow folding of the first frame element and the second frame element relative to each other; wherein the first structural load carrying member is positioned relative to the second structural load carrying member to allow direct fastening between the first structural load carrying member and the second structural load carrying member from outside the foldable building unit. 2. The foldable building unit of claim 1, wherein the foldable building unit has a structural metal frame and the first frame element, the second frame element, the first structural load carrying member and the second structural load carrying member are part of the structural metal frame. 3. The foldable building unit of claim 1, wherein the first structural load carrying member is a metal C-channel having a web and positioned relative to the second structural load carrying member to allow direct fastening through the web of the metal C-channel between the first structural load carrying member and the second structural load carrying member from outside the foldable building unit. 4. The foldable building unit of claim 1, wherein the first structural load carrying member is selected from the group comprising a metal C-channel and a metal I-beam, with a blocking member affixed lengthwise to an interior surface of the first structural load carrying member, and the first structural load carrying member is oriented and positioned such that exterior finishing materials can be directly attached to the blocking member. 5. The foldable building unit of claim 1, wherein the first structural load carrying member is selected from the group comprising a metal C-channel and a metal I-beam, with a blocking member affixed lengthwise to an interior surface of the first structural load carrying member, the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected such that when the first frame element and second frame element are in unfolded configuration, the first structural load carrying member is positioned relative to the second structural load carrying member to allow direct lengthwise fastening between the first structural load carrying member and the second structural load carrying member from outside the foldable building unit to form a fixed connection between the first frame element and the second frame element; and the first structural load carrying member is oriented and positioned such that exterior finishing material can be directly attached to the blocking member. 6. The foldable building unit of claim 1, wherein the foldable building unit comprises a first panel connected to a second panel to form an exterior edge of the foldable building unit, the first panel including (a-i) the first frame element, (a-ii) insulation material within the first panel, and (a-iii) one or more blocking members directly attached to the first frame element; and a second panel including (b-i) the second frame element, (b-ii) insulation material within the second panel, and (b-iii) one or more blocking members directly attached to the second frame element; and the first structural load carrying member and the second structural load carrying member being thermally insulated with the insulation material of the first and/or second panel, or with one or more blocking members of the first and/or second panel to reduce heat transfer through the exterior edge. 7. The foldable building unit claim 6, wherein the first panel and the second panel further comprise finishing material directly affixed to the blocking members. 8. The foldable building unit of claim 1, wherein the first structural load carrying member and the second structural load carrying member have substantially the same structural load carrying properties. 9. The foldable building unit of claim 1, wherein the first structural load carrying member and the second structural load carrying member have cross-sectional areas that differ by not more than a factor of ten. 10. The foldable building unit of claim 1, wherein the first structural load carrying member and the second structural load carrying member are not both metal I-beams, and have cross-sectional areas that differ by not more than a factor of three. 11. The foldable building unit of claim 1, wherein the first structural load carrying member and the second structural load carrying member are not both a metal C-channel or a metal I-beam. 12. The foldable building unit of claim 1, wherein the first structural load carrying member and the second structural load carrying member are foldably connected with a metal hinge. 13. The foldable building unit of claim 1, wherein the first structural load carrying member and the second structural load carrying member are positioned to form a part of an exterior edge of the foldable building unit, the first structural load carrying member being closer to the exterior edge than the second structural load carrying member, and the first structural load carrying member being a metal C-channel or a metal I-beam with a blocking member affixed lengthwise to an interior surface of the first structural load carrying member, and the first structural load carrying member oriented such that the blocking member is accessible from outside the foldable building unit. 14. The foldable building unit of claim 1, wherein at least three structural load carrying members form the first frame element and at least three structural load carrying members form the second frame element. 15. The foldable building unit of claim 1, wherein the a side of the first structural load carrying member substantially abuts a side of the second structural load carrying member. 16. The foldable building unit of claim 1, wherein the first frame element and the second frame element are part of the structural frame of a foldable building. 17. The foldable building unit of claim 1, wherein the foldable building unit is a residential building. 18. The foldable building unit of claim 1, wherein the foldable building unit is a building with a building envelope that is substantially entirely formed by panels that are connected through structural load carrying members that are, independently, a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, a metal angle beam, or a metal wide-flange beam. 19. The foldable building unit of claim 18, wherein structural load carrying members in edges of the building envelope have blocking members attached to inside surfaces of the structural load carrying members, and exterior finishing material is attached to the blocking members. 20. The foldable building unit of claim 1, wherein the foldable building unit in unfolded configuration is in substantially finished condition. 21. The foldable building unit of claim 1, wherein the first structural load carrying member and the second structural load carrying members are affixed to each other in a manner that allows substantial structural load transfer between the first structural load carrying member and the second structural load carrying member without structural failure. 22. A foldable building unit, comprising (a) a first frame element having a first structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, a metal angle beam, and a metal wide-flange beam;(b) a second frame element having a second structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, and a metal wide-flange beam; provided that the first structural load carrying member and the second structural load carrying member are not both hollow structural metal sections; and (i) the first structural load carrying member and the second structural load carrying member are lengthwise connected to form a fixed connection between the first frame element and the second frame element, or (ii) the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected to allow folding of the first frame element and the second frame element relative to each other; wherein the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected such that when the first frame element and second frame element are in unfolded configuration relative to each other, the first structural load carrying member is positioned relative to the second structural load carrying member to allow direct lengthwise fastening between the first structural load carrying member and the second structural load carrying member from outside the foldable building unit to form a fixed connection between the first frame element and the second frame element. 23. A foldable building unit, comprising (a) a first frame element having a first structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, a metal angle beam, and a metal wide-flange beam;(b) a second frame element having a second structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, and a metal wide-flange beam; provided that the first structural load carrying member and the second structural load carrying member are not both hollow structural metal sections; and (i) the first structural load carrying member and the second structural load carrying member are lengthwise connected to form a fixed connection between the first frame element and the second frame element, or (ii) the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected to allow folding of the first frame element and the second frame element relative to each other; wherein the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected with an offset hinge adapted and positioned to offset a first panel including the first frame element from a second panel including the second frame element when the first frame element and the second frame element are in folded configuration to thereby position the first panel in substantially parallel position to the second panel. 24. The foldable building unit of claim 23, wherein the first structural load carrying member and the second structural load carrying member are not both a metal C-channel or a metal I-beam. 25. A foldable building unit, comprising (a) a first frame element having a first structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, a metal angle beam, and a metal wide-flange beam;(b) a second frame element having a second structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, and a metal wide-flange beam; provided that the first structural load carrying member and the second structural load carrying member are not both hollow structural metal sections; and (i) the first structural load carrying member and the second structural load carrying member are lengthwise connected to form a fixed connection between the first frame element and the second frame element, or (ii) the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected to allow folding of the first frame element and the second frame element relative to each other; wherein the foldable building unit comprises a first panel including the first frame element and a second panel including the second frame element, and the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected with an offset hinge adapted and positioned to remain within the first panel and/or second panel. 26. A foldable building unit, comprising (a) a first frame element having a first structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, a metal angle beam, and a metal wide-flange beam;(b) a second frame element having a second structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, and a metal wide-flange beam; provided that the first structural load carrying member and the second structural load carrying member are not both hollow structural metal sections; and (i) the first structural load carrying member and the second structural load carrying member are lengthwise connected to form a fixed connection between the first frame element and the second frame element, or (ii) the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected to allow folding of the first frame element and the second frame element relative to each other; The foldable building unit of claim 1, wherein at least the first or the second structural load carrying member has a blocking member affixed lengthwise to an interior surface of the structural load carrying member, and the blocking member is positioned such that exterior finishing material can directly be affixed to the blocking member. 27. The foldable building unit of claim 26, wherein the first structural load carrying member is selected from the group comprising a metal C-channel and a metal I-beam, with a blocking member affixed lengthwise to an interior surface of the first structural load carrying member, and the first structural load carrying member is oriented and positioned such that exterior finishing materials can be directly attached to the blocking member. 28. The foldable building unit of claim 26, wherein the first structural load carrying member is selected from the group comprising a metal C-channel and a metal I-beam, with a blocking member affixed lengthwise to an interior surface of the first structural load carrying member, the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected such that when the first frame element and second frame element are in unfolded configuration, the first structural load carrying member is positioned relative to the second structural load carrying member to allow direct lengthwise fastening between the first structural load carrying member and the second structural load carrying member from outside the foldable building unit to form a fixed connection between the first frame element and the second frame element; and the first structural load carrying member is oriented and positioned such that exterior finishing material can be directly attached to the blocking member. 29. The foldable building unit of claim 26, wherein the first structural load carrying member and the second structural load carrying member are foldably connected with a metal hinge. 30. A foldable building unit, comprising (a) a first frame element having a first structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, a metal angle beam, and a metal wide-flange beam;(b) a second frame element having a second structural load carrying member selected from the group comprising a hollow structural metal section, a metal C-channel, a metal I-beam, a metal T-beam, and a metal wide-flange beam; provided that the first structural load carrying member and the second structural load carrying member are not both hollow structural metal sections; and (i) the first structural load carrying member and the second structural load carrying member are lengthwise connected to form a fixed connection between the first frame element and the second frame element, or (ii) the first structural load carrying member and the second structural load carrying member are lengthwise foldably connected to allow folding of the first frame element and the second frame element relative to each other; wherein the first structural load carrying member and the second structural load carrying member are affixed lengthwise to each other. 31. The foldable building unit of claim 30, wherein the first structural load carrying member and the second structural load carrying member are welded to each other or affixed with self-drilling fasteners.
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