(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)

9
(l ) Worl ;::: :!Property 1111111111111111IIIIIIIIIIIIIIIIIIIIIIIIIIIIIlllllllllllllllllllllllllll11111111111111111111111

International Bureau (towlnt)oern2atoio2na2I/P2ub3lilca6ti7on5NAumlber

(43) International Publication Date ;;;;;..,,-""
03 November 2022 (03.11.2022) WI PO I PCT

(51) International Patent Classification: GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, ST, SZ,
E04B 1/38 (2006.01) B23P 11/00 (2006.01) TZ, UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU,
F16B 9/00 (2006.01) B23P 17/00 (2006.01) TJ, TM), European (AL, AT, BE, BG, CH, CY, CZ, DE,
E04F 15102 (2006.01) E04C 2/284 (2006.01) DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT,
F16B 5/02 (2006.01) LU, LV,
(21) International Application Number: MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM,
PCT/US2022/014224 TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW,
KM, ML, MR, NE, SN, TD, TG).
(22) International Filing Date:
28 January 2022 (28.01.2022) Published:
- with international search report (Art. 21(3))
(25) Filing Language:
English
(26) Publication Language:
English
(30) Priority Data:
63/181,447 29 April 2021 (29.04.2021)
63/188,lOl 13 May 2021 (13.05.2021) us
63/192,349 24 May 2021 (24.05.2021)
us
63/196,400 03 June 2021 (03.06.2021)
us
63/211,712 17 June 2021 (17.06.2021) us
us
17/504,883 19 October 2021 (19.10.2021) us
PCT/US202l/056415
25 October202l (25.10.2021) us
-
iiiiiiii
iiiiiiii
(71) Applicant: BUILD IP LLC [US/US]; 5345 East North
Belt Road, North Las Vegas, NV 89115 (US).

-
iiiiiiii

!!!!!!!!
(72) Inventors: TIRAMANI, Paolo; 3726 South Las Vegas
Boulevard, Las Vegas, NV 89103 (US). TIRAMANI,
Galiano; 10322 Mystic Pine Road, Las Vegas, NV 89135
(US). DENMAN, Kyle; 5327 Daywood Street, North Las

--
Vegas, NV 8903 l (US).
(74) Agent: MACDAVITT, Sean, R. et al.; Mccarter & Eng
iiiiiiii lish, LLP, 265 Franklin Street, Boston, MA 02 l lO (US).

- !!!
(81) Designated States (unless otherwise indicated, for every
kind of national protection available): AE, AG, AL, AM,
AO, AT, AU, AZ, BA, BB, BG, EH, EN, BR, BW, BY,
BZ,
CA, CH, CL, CN, CO, CR, CU, CZ, DE, DJ, DK, DM, DO,
!!!!! DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT, HN,
HR, HU, ID, IL, IN, IR, IS, IT, JO, JP, KE, KG, KH, KN,

-
KP, KR, KW, KZ, LA, LC, LK, LR, LS, LU, LY, MA, MD,
ME, MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO,
NZ, OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW,

-
!!!!!!!!

!!!!!!!!
SA, SC, SD, SE, SG, SK, SL, ST, SV, SY, TH, TJ, TM, TN,
TR, TT, TZ, UA, UG, US, UZ, VC, VN, WS, ZA, ZM, ZW.
iiiiiiii (84) Designated States (unless otherwise indicated, for every
iiiiiiii
kind of regional protection available): ARIPO (BW, GH,

(54) Title: WALL COMPONENT APPURTENANCES

(57) Abstract: A toe screw housing, for securing abutting enclosure components together, having a bearing plate with an interior
face, an exterior face and a beveled upper edge; a toe screw well joined to and extending away from the interior face and including a
fastener shelf; a toe screw support joined to the interior face, and additionally joined to and extending away from the fastener shelf,
the toe screw support distal from the fastener shelf including a planar support surface oriented perpendicular to the interior face; and a
fastener bore passing through the fastener shelf, the toe screw support and the support surface and inclined at a second angle relative
to the interior face of the bearing plate.
 WO 2022/231675 PCT/0S2022/014224

WALL COMPONENT APPURTENANCES

CROSS-REFERENCES TO RELATED APPLICATION

[0001] This application is a continuation in part application of PCT Patent Application No.
PCT/US2021/056415, filed October 25, 2021, which claims the benefit of U.S. Provisional
Application Nos. 63/196,400, filed June 3, 2021; 63/181,447, filed April 29, 2021; and
63/136,268, filed January 12, 2021; and a continuation in part application of U.S.
Nonprovisional Application No. 17/504,883, filed October 19, 2021; which claims the
benefit of U.S. Provisional Application Nos. 63/196,400, filed June 3, 2021; 63/181,447,
filed April 29, 2021; and 63/136,268, filed January 12, 2021; and this application claims the
benefit of U.S. Provisional Application Nos. 63/211,712, filed June 17, 2021; 63/196,400,
filed June 3, 2021; 63/188,101, filed May 13, 2021; 63/192,349, filed May 24, 2021; and
63/181,447, filed April 29, 2021.

BACKGROUND OF THE INVENTION

Field of the Invention

[0002] The inventions herein relate to structures, such as dwellings and other buildings for
residential occupancy, commercial occupancy and/or material storage, and to components
for such structures.

Description of the Related Art

[0003] In the field of residential housing, the traditional technique for building homes is
referred to as "stick-built" construction, where a builder constructs housing at the intended
location using in substantial part raw materials such as wooden boards, plywood panels, and
steel columns. The materials are assembled piece by piece over a previously prepared
portion of ground, for example, a poured concrete slab or a poured concrete or cinder block
foundation.

[0004] There have been a variety of efforts to depart from the conventional construction
techniques used to create dwellings, as well as commercial spaces and like, in an effort to
reduce costs. In this regard, significant advancements in the construction of dwellings and
commercial space have been made by the current inventors, as exemplified by their patent
documents, including U.S. Patent Nos. 8,474,194, 8,733,029, 10,688,906, 10,829,029,
10,926,689 and 11,220,816. In one aspect, these patents pertain to fabricating wall, floor

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 WO 2022/231675 PCT/0S2022/014224

and roof components in a factory that are folded together into a compact shipping module,
and which are then transported to the intended location and unfolded to yield a fully formed
structure.

SUMMARY OF THE INVENTION

[0005] The present inventions describe advancements in the design of appurtenances for
building structures, particularly for the wall components of such structures.

[0006] In a first aspect, the present inventions are directed to a toe screw housing for
securing abutting enclosure components together. The toe screw housing comprises a
bearing plate with a planar interior face, a planar exterior face and a beveled upper edge
beveled at a non-perpendicular first angle relative to the exterior face. There is provided a
toe screw well, joined to and extending away from the interior face of the bearing plate,
which includes a fastener shelf, and there is provided a toe screw support that is joined to
the interior face of the toe screw housing, and which is also joined to and extending away
from the fastener shelf. The toe screw support distal from the fastener shelf includes a
planar support surface oriented perpendicular to the interior face. A fastener bore passes
through the fastener shelf, the toe screw support and the support surface, and is inclined at a
non-perpendicular second angle relative to the interior face of the bearing plate.

[0007] In a second aspect, the present inventions are directed to a baseboard for masking a
toe screw bearing plate that has a beveled upper edge. The baseboard comprises a planar
elongate member having an elongate interior face, an elongate top edge and an elongate
bottom edge. An elongate hook ledge is joined to the top edge of the base board to form a
wedge-shaped angled slot that is oriented to be open in the direction of the bottom edge,
with the wedge-shaped angled slot configured to be positioned over the beveled upper edge
of the bearing plate. There is provided an elongate linear first step positioned on the interior
face below the angled slot to form an elongate first recess on the interior face configured to
receive the toe screw bearing plate, and there is provided an elongate second step positioned
on the interior face below the elongate first step to form an elongate second recess on the
interior face.

[0008] These and other aspects of the present inventions are described in the drawings
annexed hereto, and in the description of the preferred embodiments and claims set forth
below.

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 WO 2022/231675 PCT/0S2022/014224

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a perspective view of a structure prepared in accordance with the present
inventions.

[0010] Figure 2 is a top schematic view of the structure shown in Figure 1.

[0011] Figure 3 is an end view of a shipping module from which is formed the structure
shown in Figure 1.

[0012] Figures 4 and 5 are partial cutaway views of a structure in accordance with the
present inventions, depicting in greater detail aspects of the roof, wall and floor
components.

[0013] Figure 6 is a schematic perspective view depicting the exterior edge reinforcement
for a wall component in accordance with the present inventions.

[0014] Figure 7 is an exploded cross-sectional view of a multi-layered, laminate design for

use in the enclosure components of the present inventions.

[0015] Figure 8A is a front perspective view of a toe screw housing in accordance with the
present inventions, Figure 8B is a rear perspective view (looking upward) of a toe screw
housing in accordance with the present inventions, and Figure 8C is a side view of a toe
screw housing in accordance with the present inventions.

[0016] Figures 9A, 9B and 9C are respectively front perspective, rear perspective and side
views of an interior baseboard in accordance with the present inventions.

[0017] Figure 10A is a side section view depicting a toe screw housing and an interior
baseboard portion for a wall component in accordance with the present inventions, Figure
1OB is a side section view depicting a junction between a wall portion and a floor portion
secured by a fastener inserted through a toe screw housing, and Figure lOC is a perspective
cutaway view of representative placements of toe screw housings in accordance with the
present inventions.

[0018] Figures 1 lA, 1 lB and 1 lC are respectively perspective, top and side cutaway
views of a fixed space portion of a structure in accordance with the present inventions.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] An embodiment of the foldable, transportable structure 150 in which the inventions
disclosed herein can be implemented is depicted in Figures 1 through 5. When fully

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 WO 2022/231675 PCT/0S2022/014224

unfolded, as exemplified by Figure 1, structure 150 has a rectangular shape made of three
types of generally planar and rectangular enclosure components 155, the three types of
enclosure components 155 consisting of a wall component 200, a floor component 300, and
a roof component 400. As shown in Figures I and 2, the perimeter of structure 150 is
defined by first longitudinal edge 106, first transverse edge 108, second longitudinal edge
116 and second transverse edge 110. For convenience, a direction parallel to first
longitudinal edge 106 and second longitudinal edge 116 may be referred to as the
"longitudinal" direction, a direction parallel to first transverse edge I08 and second
transverse edge 110 may be referred to as the "transverse" direction; and a direction parallel
to the vertical direction in Figure I may be referred to as the "vertical" direction. Structure
150 as shown has one floor component 300, one roof component 400 and four wall
components 200; although it should be understood that the present inventions are
applicable to structures having other configurations as well.

[0020] Enclosure components 155 (wall component 200, floor component 300 and roof
component 400) can be fabricated and dimensioned as described herein and positioned
together to form a shipping module 100, shown end-on in Figure 3. The enclosure
components 155 are dimensioned so that the shipping module 100 is within U.S. federal
highway dimensional restrictions. As a result, shipping module 100 can be transported over
a limited access highway more easily, and with appropriate trailering equipment,
transported without the need for oversize permits. Thus, the basic components of structure
150 can be manufactured in a factory, positioned together to form the shipping module 100,
and the modules 100 can be transported to the desired site for the structure, where they can
be readily assembled, as described herein.

Enclosure Component (155): General Description

[0021] The enclosure components 155 of the present invention include a number of shared
design features that are described below.

A. Laminate Structure Design

[0022] Enclosure components 155 can be fabricated using a multi-layered, laminate

design. A particular laminate design that can be used to fabricate enclosure components
155 comprises a first structural layer 210, a foam panel layer 213, a second structural layer
215 and a protective layer 218, as shown in Figure 7 and described further below.

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 WO 2022/231675 PCT/0S2022/014224

[0023] In particular, first structural layer 210 is provided in the embodiment of enclosure
component 155 that is depicted in Figure 7. First structural layer 210 in the embodiment
shown comprises a sheet metal layer 205, which can be for example galvanized steel or
aluminum. Sheet metal layer 205 is made from a plurality of generally planar rectangular
metal sheets 206 positioned adjacent to each other to generally cover the full area of the
intended enclosure component 155.

[0024] Referring again to Figure 7, there is next provided in the depicted embodiment of
enclosure component 155 a foam panel layer 213, comprising a plurality of generally
planar rectangular foam panels 214 collectively presenting a first face 211 and a second
opposing face 212. Foam panels 214 are made for example of expanded polystyrene (EPS)
foam. A number of these foam panels 214 are positioned adjacent to each other and
superposed first face-down on first structural layer 210 to generally cover the full area of
the intended enclosure component 155. The foam panels 214 of foam panel layer 213
preferably are fastened to first structural layer 210 using a suitable adhesive, preferably a
polyurethane based construction adhesive.

[0025] In the embodiment of the enclosure component 155 depicted in Figure 7, there is
next provided a second structural layer 215, having a first face that is positioned on the
second opposing face 212 of foam panels 214 (the face distal from first structural layer
210), and also having a second opposing face. Second structural layer 215 in the
embodiment shown comprises a sheet metal layer 216, which can be for example
galvanized steel or aluminum. Sheet metal layer 216 is made from a plurality of generally
planar rectangular metal sheets 217 positioned adjacent to each other and superposed first
face-down on the second opposing face of foam panel layer 213 to generally cover the
full area of the intended enclosure component 155. The metal sheets 217 of second
structural layer 215 preferably are fastened to foam panel layer 213 using a suitable
adhesive, preferably a polyurethane based construction adhesive.

[0026] In the embodiment of the enclosure component 155 depicted in Figure 7, there is
optionally next provided a protective layer 218, having a first face that is positioned on the
second opposing face of second structural layer 215 (the face distal from foam panel layer
213), and also having a second opposing face. Optional protective layer 218 in the
embodiment shown comprises a plurality of rectangular structural building panels 219
principally comprising an inorganic composition of relatively high strength, such as
magnesium oxide (MgO). The structural building panels 219 are positioned adjacent to

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 WO 2022/231675 PCT/0S2022/014224

each other and superposed first face-down on the second opposing face of second structural
layer 215 to generally cover the full area of the intended enclosure component 155. The
building panels 219 of protective layer 218 preferably are fastened to second structural
layer 215 using a suitable adhesive, preferably a polyurethane based construction adhesive.
Protective layer 218 can be used if desired to impart a degree of fire resistance to the
enclosure component 155, as well as to provide a pleasing texture and/or feel.

[0027] Other embodiments of multi-layered, laminate designs that can be used to fabricate
the enclosure components 155 of the present invention, are described in U.S.
Nonprovisional Patent Application No. 16/786,130, entitled "Foldable Building Structures
with Utility Channels and Laminate Enclosures," filed on February 10, 2020 and now
issued as U.S. Patent No. 11,118,344. The contents of that U.S. Nonprovisional Patent
Application No. 16/786,130, entitled "Foldable Building Structures with Utility Channels
and Laminate Enclosures" and filed on February 10, 2020 are incorporated by reference as
if fully set forth herein, particularly including the multi-layered, laminate designs described
for example at CJ{CJ{ 0034-57 and depicted in Figures 4A-4D thereof.

B. Enclosure Component Exterior Edge Reinforcement

[0028] The exterior edges of each enclosure component 155 (i.e., the edges that define the
perimeter of enclosure component 155) can be provided with exterior edge reinforcement,
as desired. Exterior edge reinforcement generally comprises an elongate, rigid member
which can protect foam panel material that would otherwise be exposed at the exterior
edges of enclosure components 155. Exterior edge reinforcement can be fabricated from
one or more of laminated strand lumber board, wooden board, C-channel extruded
aluminum or steel, or the like, and is generally secured to the exterior edges of enclosure
component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.

C. Enclosure Component Partitioning

[0029] Enclosure components 155 in certain instances are partitioned into enclosure
component portions to facilitate forming a compact shipping module 100. In those
instances where an enclosure component 155 is partitioned into enclosure component
portions, any exterior edge reinforcement on the exterior edges defining the perimeter of
the enclosure component is segmented as necessary between or among the portions.

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 WO 2022/231675 PCT/0S2022/014224

[0030] The enclosure component portions can be joined by hinge structures or mechanisms
to permit the enclosure component portions to be "folded" and thereby contribute to
forming a compact shipping module 100.

D. Enclosure Component Interior Edge Reinforcement

[0031] An enclosure component 155 partitioned into enclosure component portions will
have interior edges. There will be two adjacent interior edges for each adjacent pair of
enclosure component portions. Such interior edges can be provided with interior edge
reinforcement. Similar to exterior edge reinforcement, such interior edge reinforcement
generally comprises an elongate, rigid member which can protect foam panel material that
would otherwise be exposed at the interior edges of enclosure components 155. Interior
edge reinforcement can be fabricated from one or more of laminated strand lumber board,
wooden board, C-channel extruded aluminum or steel, or the like, and is generally
secured to the interior edges of enclosure component 155 with fasteners, such as screw or
nail fasteners, and/or adhesive.

E. Enclosure Component Load Transfer

[0032] In the case of enclosure components 155, it is necessary to transfer the loads
imposed on their surfaces to their exterior edges, where those loads can be transferred
either to or through adjoining walls, or to the building foundation. For enclosure
components 155 that are horizontally oriented when in use (floor component 300 and roof
component 400), such loads include the weight of equipment, furniture and people borne by
their surfaces, as well as vertical seismic loads. For enclosure components that are
vertically oriented when in use (wall component 200), such loads include those arising
from meteorological conditions (hurricanes, tornadoes, etc.) and human action (vehicle and
other object impacts).

[0033] For this purpose, multi-layered, laminate designs as shown in Figure 7 will function
to transfer the loads described above. To add additional load transfer capability, structural
members, such as beams and/or joists, can be utilized within the perimeter of the enclosure
components 155, as is deemed appropriate to the specific design of structure 150 and the
particular enclosure component 155, to assist in the transfer of loads to the exterior edges.
Particular embodiments of such structural members, which also incorporate hinge
structures, are described in U.S. Nonprovisional Patent Application No. 17/527,520 entitled
"Folding Beam Systems", filed November 16, 2021 and having the same inventors as this

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 WO 2022/231675 PCT/0S2022/014224

disclosure. The contents of that U.S. Nonprovisional Patent Application No. 17/527,520
entitled "Folding Beam Systems", filed November 16, 2021 and having the same inventors
as this disclosure, is incorporated by reference as if fully set forth herein, particularly the
description of the hinged load transfer components set forth for example in CJ{CJ{ 0074-0089
and 0104-0126 and in Figures 8A-13E and 15A-24A thereof, as well as the description of
the associated end hinge assemblies set forth for example in CJ{CJ{ 0090-0093 and 0127-0132
and in Figures 14A-14B, 24B and 25A-25D thereof.

F. Enclosure Component Sealing Systems

[0034] Structure 150 comprises a number of wall, floor and roof components with abutting
or exposed exterior edges, as well as a number of partitioned wall, floor and roof
components with interior edges. In this regard, sealing structures can be utilized, with the
objective to limit or prevent the ingress of rain water, noise and outside air across these
exterior and interior edges into the interior of structure 150.

[0035] Particular sealing structures for accomplishing the foregoing objective are described
in PCT Patent Application No. PCT/US21/56415, entitled "Enclosure Component Sealing
Systems," filed on October 25, 2021 and having the same inventors as the present
application. The contents of that PCT Patent Application No. PCT/US21/56415, entitled
"Enclosure Component Sealing Systems," filed on October 25, 2021 and having the same
inventors as this disclosure, are incorporated by reference as if fully set forth herein,
particularly including the sealing systems described for example at CJ{CJ{ 0080-0167 and
depicted in Figures 9-20 thereof, and also including the exemplary placements for such
sealing systems described in CJ{CJ{ 0168-0174 and depicted in Figures 8A-8B thereof.

[0036] Further design details of wall component 200, floor component 300, and roof
component 400 are provided in the sections following.

Wall Component (200)

[0037] Typically, structure 150 will utilize four wall components 200, with each wall
component 200 corresponding to an entire wall of structure 150.

A. General Description

[0038] Wall component 200 has a generally rectangular perimeter. As shown in Figure 1,
wall components 200 have plural apertures, specifically a door aperture 202, which has a
door frame and door assembly, and plural window apertures 204, each of which has a

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 WO 2022/231675 PCT/0S2022/014224

window frame and a window assembly. The height and length of wall components 200 can
vary in accordance with design preference, subject as desired to the dimensional restrictions
applicable to transport, described above. In this disclosure, structure 150 is fashioned with
all sides of equal length; accordingly, its first and second longitudinal edges 106 and 116,
and its first and second transverse edges 108 and 110, are all of equal length. It should be
understood however, that the inventions described herein are applicable to structures
having other dimensions, such as where two opposing wall components 200 are longer than
the other two opposing wall components 200.

[0039] As indicated above, wall components 200 of the present inventions can utilize a
multi-layered, laminate design. In the embodiment depicted in Figures 1 through 6, wall
component 200 utilizes the multi-layered, laminate design shown in Figure 7 employing
these particular elements: sheet metal layer 205 of first structural layer 210 is 24 gauge
galvanized steel approximately 0.022 - 0.028 inch thick, the foam panels 214 of foam
panel layer 213 are EPS foam approximately 5.68 inches thick, the sheet metal layer 216 of
second structural layer 215 is 24 gauge galvanized steel approximately 0.022 - 0.028 inch
thick, and the building panels 219 of protective layer 218 are MgO board approximately
0.25 inch (6 mm) thick.

[0040] The perimeter of each wall component 200 is generally provided with exterior edge
reinforcement. As exemplified by wall component 200 shown in Figure 6, the exterior edge
reinforcement for wall component 200 is a floor plate 220 along the bottom horizontal edge,
a ceiling plate 240 along the top horizontal edge and two end pieces 270 respectively
fastened at each vertical edge of wall component 200. In the case of a wall component 200,
exterior edge reinforcement provides regions for fastening like regions of abutting wall
components 200, roof component 400 and floor component 300, in addition to protecting
the exterior edges of foam panel material. In the embodiment shown in Figures 1 through 6,
the exterior edge reinforcement for wall component 200 provided by floor plate 220, ceiling
plate 240, and end pieces 270 is fabricated from laminated strand lumber board 5.625" deep
and 1.5" thick.

B. Partitioned Wall Components

[0041] Referring to Figure 2, structure 150 has two opposing wall components 200,
where one of the two opposing wall components 200 comprises first wall portion 200s- l
and second wall portion 200s-2, and the other of the two opposing wall components 200

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 WO 2022/231675 PCT/0S2022/014224

comprises third wall portion 200s-3 and fourth wall portion 200s-4. Each of wall portions
200s- l, 200s-2, 200s-3 and 200s-4 has a generally rectangular planar structure. As shown
in Figure 2, the interior vertical edge 192-1 of wall portion 200s- l is proximate to a
respective interior vertical edge 192-2 of wall portion 200s-2, and the interior vertical
edge 194-3 of wall portion 200s-3 is proximate a respective interior vertical wall edge
194-4 of wall portion 200s-4. Interior edge reinforcement can be provided at any one or
more of vertical edges 192-1, 192-2, 194-3 and 194-4. In the embodiment shown in
Figures 1
through 6, the interior edge reinforcement provided at vertical edges 192-1, 192-2, 194-3
and 194-4 is fabricated from laminated strand lumber board 5.625" deep and 1.5" thick.

[0042] Referring again to Figure 2, first wall portion 200s- l is fixed in position on floor
portion 300a proximate to first transverse edge 108, and third wall portion 200s-3 is fixed
in position on floor portion 300a, opposite first wall portion 200s- l and proximate to
second transverse edge 110. First wall portion 200s-l is joined to second wall portion
200s-2 with a hinge structure that permits wall portion 200s-2 to pivot about vertical axis
192 between a folded position and an unfolded position, and third wall portion 200s-3 is
joined to fourth wall portion 200s-4 with a hinge structure to permit fourth wall portion
200s-4 to pivot about vertical axis 194 between a folded position and an unfolded position.

[0043] Notably, first wall portion 200s-l is longer than third wall portion 200s-3 by a
distance approximately equal to the thickness of wall component 200, and second wall
portion 200s-2 is shorter than fourth wall portion 200s-4 by a distance approximately equal
to the thickness of wall component 200. Furthermore, wall portion 200s- l and wall
portion 200s-3 are each shorter in length (the dimension in the transverse direction) than
the dimension of floor portion 300a in the transverse direction. Dimensioning the lengths
of wall portions 200s- l, 200s-2, 200s-3 and 200s-4 in this manner permits wall portions
200s- 2 and 200s-4 to nest against each other in an overlapping relationship when in an
inwardly folded position. In this regard, Figure 2 depicts wall portions 200s-2 and 200s-4
both in their unfolded positions, where they are labelled 200s-2u and 200s4-u respectively,
and Figure 2 also depicts wall portions 200s-2 and 200s-4 both in their inwardly folded
positions, where they are labelled 200s-2f and 200s4-frespectively. When wall portions
200s-2 and 200s-4 are in their inwardly folded positions (200s-2f and 200s-4f), they
facilitate forming a compact shipping module. When wall portion 200s-2 is in its unfolded
position (200s-2u), it forms with wall portion 200s-l a wall component 200 proximate first
transverse edge 108, and when wall portion 200s-4 is in its unfolded position (200s-4u), it
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 WO 2022/231675 PCT/0S2022/014224

forms with wall portion 200s-3 a wall component 200 proximate second transverse edge
110.

[0044] The hinge structures referenced for securing first wall portion 200s-l to second wall
portion 200s-2, and third wall portion 200s-3 to fourth wall portion 200s-4, can be surface
mounted or recessed, and of a temporary or permanent nature. The provision of interior
edge reinforcement, as described above, can provide a region for securing hinge structures.
Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal,
plastic or leather material.

C. Unpartitioned Wall Components

[0045] As compared to the two wall components 200 proximate first and second transverse
edges 108 and 110, which are partitioned into wall portions, the remaining two wall
components 200 proximate first and second longitudinal edges 106 and 116 do not
comprise plural wall portions, but rather each is a single piece structure. However, one of
these wall components 200, which is sometimes denominated 200P in this disclosure, and
which is located on floor portion 300b proximate first longitudinal edge 106, is pivotally
secured to floor portion 300b to permit wall component 200P to pivot about horizontal axis
105 shown in Figure 3 from a folded position to an unfolded position. Pivotally securing
wall component 200P also facilitates forming a compact shipping module 100. The
remaining wall component 200, sometimes denominated 200R in this disclosure, is rigidly
secured on floor portion 300a proximate second longitudinal edge 116 and abutting the
vertical edges of first wall portion 200s-l and third wall portion 200s-3 proximate to second
longitudinal edge 116, as shown in Figure 2.

[0046] The hinge structures described above, for securing wall component 200P to floor
portion 300b, can be surface mounted or recessed, and of a temporary or permanent nature.
The provision of exterior edge reinforcement, as described above, can provide a region for
securing hinge structures. Suitable hinge structures can be fabricated for example of metal,
plastic, leather, ferrous or non-ferrous material.

D. Wall Component Appurtenances

[0047] Certain appurtenances can be fitted to wall components 200 to facilitate fastening
them to floor component 300 (described below), as well as to improve the interior
appearance and speed fabrication.

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 WO 2022/231675 PCT/0S2022/014224

[0048] As a first appurtenance that can be fitted to wall components 200, Figures 8A-8C
depict a toe screw housing 288, whose principal components comprise a bearing plate 292,
a toe screw well 289 and a toe screw support 221. Bearing plate 292 is a planar plate of a
select thickness having a rectangular perimeter, and includes an exterior face 293, an
opposed interior face 294 and a top, bevel edge 297. Toe screw well 289 comprises a semi
cylindrical wall 298 having an axial centerline 198, shown in Figure 8C, which is oriented
at an angle cp1 from a line normal to the interior face 294 of bearing plate 292. Angle cp1 can
be in the range of forty-five (45°) to seventy (70°) degrees, such as sixty (60°) degrees. The
exterior face 293 of bearing plate 292 defines an aperture that renders the interior volume of
toe screw well 289 accessible from the exterior face side of toe screw well 289.

[0049] An upper portion of semi-cylindrical wall 298 is angularly sectioned, for example at
an angle of ninety degrees (90°) minus cp1, relative to axial centerline 198, for example in
the range of forty-five (45°) to twenty (20°) degrees, such as thirty (30°) degrees, with the
upper portion so sectioned joined to interior face 294. A lower portion of semi-cylindrical
wall 298 is further sectioned parallel to axial centerline 198, with each of the resultant two
axially-oriented edges joined to a respective triangular gusset 299. The two gussets 229 are
spatially opposed and joined to the interior face 294 of bearing plate 292. Toe screw well
289 also includes a fastener shelf 239, visible in Figure 8A, which is joined to semi
cylindrical wall 298 and each of the two gussets 299. The interior volume of toe screw well
289, which is defined by fastener shelf 239, gussets 299 and semi-cylindrical wall 298,
forms a recess within toe screw well 289 for receiving a fastener head. Fastener shelf 239
has a planar upper face that is perpendicularly oriented to the axial centerline 198 of semi
cylindrical surface 298, and a planar opposed lower face that is perpendicularly oriented to
the axial centerline 198 of semi-cylindrical surface 298. It should be noted that the upper
face of fastener shelf 239 will correspondingly be oriented at angle cp1 relative to interior
face 294 and exterior face 293.

[0050] The lower face of fastener shelf 239 is joined to a toe screw support 221. Toe screw
support 221 comprises a semi-cylindrical solid 222 and a triangular wedge 223. Semi
cylindrical solid 222 has an axial centerline 197, shown in Figure 8C, which is oriented at
an angle cp2 from a line normal to the interior face 294 of bearing plate 292. Angle cp2 can
be in the range of forty-five (45°) to seventy (70°) degrees, such as sixty (60°) degrees, and
preferably cp1 equals cp2. Centerlines 197 and 198 can be, but need not be, co-linear. The
upper portion of semi-cylindrical solid 222 is sectioned normal to axial centerline 197, with

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 WO 2022/231675 PCT/0S2022/014224

the sectioned portion joined to the lower face of fastener shelf 239, and is further
sectioned parallel to axial centerline 197 and joined to triangular wedge 223. In turn, the
upper surface of wedge 223 is joined to the lower face of fastener shelf 239, and wedge
223 is further joined at its narrow end to the interior face 294 of bearing plate 292. The
diameter of semi-cylindrical solid 222 is less than the diameter of semi-cylindrical wall
298, in the embodiment shown in Figures 8A-8C.

[0051] Toe screw support 221 also includes a support surface 224 defined by the lower
surfaces of semi-cylindrical solid 222 and wedge 223. Support surface 224 is
perpendicularly oriented to the interior face 294 of bearing plate 292. A groove 199 is cut
into the planar lower surface of support surface 224. Groove 199 is oriented parallel to the
interior face 294 of bearing plate 292, and, in the embodiment shown in the figures, is
spaced from interior face 294 a distance approximately equal to the thickness of protective
layer 218.

[0052] A fastener bore 225 passes through fastener shelf 239 and toe screw support 221,
with an exit orifice in support surface 224, thereby forming a passage through toe screw
support 221 for a fastener, the head of which can be positioned against the upper face of
fastener shelf 239. Preferably, the axial centerline of fastener bore 225 is co-linear with the
axial centerline 197 of semi-cylindrical wall 222, so that the axial centerline of fastener bore
225 is not perpendicular to the exterior face 293 of bearing plate 292, but rather is oriented
at angle cp2 from a line normal to the exterior face 293 of bearing plate 292.

[0053] Bevel edge 297 of toe screw housing 288 forms an angle cp3 with exterior face 293
to provide a sloped bevel surface between the end of bevel edge 297 and interior face 294 of
bearing plate 292. Accordingly, angle cp3 is not perpendicular to the exterior face 293 of
bearing plate 292, but rather is an acute angle, such as forty-five degrees (45°) or less, and
in particular twenty degrees (20°).

[0054] As a second appurtenance that can be fitted to wall components 200, Figures 9A-9C
depict an interior baseboard 140. Interior baseboard 140 is a planar elongate member with a
planar elongate exterior face 141, a planar elongate interior face 142, an elongate top edge
143 and an elongate bottom edge 144. An elongate hook ledge 145 is joined along the top
edge 143 of interior baseboard 140 and forms a downward facing wedge-shaped angled slot
146 that has an interior angle cp4, shown in Figure 9C, which is preferably the same as angle
cp3 of bevel edge 297, or nearly so. Interior face 142 has an elongate linear first step 147

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positioned below angled slot 146, so as to define an elongate bearing plate recess 148
between angled slot 146 and first step 147 sufficiently wide to receive bearing plate 292.
Positioned below first step 147, interior face 142 has an elongate linear second step 137
that extends a distance from bottom edge 144, so as to define a fastening recess 138
between first step 147 and second step 138.

[0055] For wall components 200 utilizing the laminate design shown in Figure 7, a
plurality of toe screw housings 288 can be fastened at space-apart intervals in proximity to
the bottom of the wall components 200, as shown in Figure IOC. As shown in Figure IOA,
each toe screw housing 288 is positioned so that the support surface 224 of its toe screw
support 221 rests upon the floor plate 220 of the wall component 200. Select portions of the
foam panel layer 213, sheet metal layer 216 and protective layer 218 are removed to provide
a space to receive the toe screw well 289 and toe screw support 221 of the toe screw
housing 288, and so that the interior face 294 of bearing plate 292 of the toe screw housing
288 lies against protective layer 218. As described above, the distance from groove 199 to
interior face 294 of bearing plate 292 is approximately equal to the thickness of protective
layer 218. When so dimensioned, groove 199 can engage the edge of sheet metal layer 216
immediately below the removed portion thereof, as shown in Figure IOA.

[0056] Plural toe screw housings 288 can be utilized to fasten both partitioned and
unpartitioned wall components 200 to floor component 300 (described below). For
example, referring to Figures IOB and IOC, toe screw housings 288 are shown being
utilized in connection with both wall portion 200s-4 and wall component 200P. Following
their unfolding (described below), a fastener, such as a SIP screw 136 can be inserted into
fastener bore 225, as illustrated in Figure IOA, and driven into the exterior edge
reinforcement of both the wall component 200 and the underlying floor component 300,
specifically floor plate 220 and footing beam 320 respectively, as shown in Figure IOB, to
fasten the wall component 200 to the floor component 300.

[0057] Plural toe screw housings 288 can also be utilized to fasten each of fixed wall
component 200R, fixed wall portion 200s-l, fixed wall portion 200s-3 and pivoting wall
portion 200s-2 to floor component 300. In the case of wall component 200R and fixed wall
portions 200s-l and 200s-3, the fastening operation just described can be undertaken during
factory fabrication of fixed space portion 102, described further below.

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[0058] In using toe screw housings 288 to fasten wall component 200P to floor section
300b, it can be seen in Figure lOB that one or more screws 136 will also pass through two
sealing structures, wall end cap 246 and floor top plate 252, which are present at the
junction of wall component 200P and floor portion 300b. A similar sealing structure
arrangement is present in the cases of the junction between wall component 200R and floor
portion 300a, the junction between fixed wall portion 200s- l and floor portion 300a, and
the junction between wall portion 200s-3 and floor component 300a. A more detailed
description of these sealing structures is set forth in PCT Patent Application No.
PCT/US21/56415, entitled "Enclosure Component Sealing Systems," filed on October 25,
2021 and having the same inventors as the present application, for example in CJICJI 0092,
0097-0101 and 0112-0120, and in connection with Figures 12 and 15, of that application.
The contents of that PCT Patent Application No. PCT/US21/56415, entitled "Enclosure
Component Sealing Systems," filed on October 25, 2021 and having the same inventors as
this disclosure, are incorporated by reference as if fully set forth herein, particularly
including the wall end cap 246 and floor top plate 252 described for example at CJ{CJ{ 0092,
0097-0101 and 0112-0120, and in connection with Figures 12 and 15, of that application.

[0059] In using toe screw housings 288 to fasten wall portions 200s-2 and 200s-4 to floor
portions 300a and 300b, one or more screws 136 will also pass through sealing structures
that are present at the junction of pivoting wall portion 200s-2 in its unfolded position and
floor portions 300a/300b, and at the junction of pivoting wall portion 200s-4 in its unfolded
position and floor portions 300a/300b. However, these sealing structures, namely wall end
interlock A 262 (not shown) and floor top interlock 261 (not shown), differ from wall end
cap 246 and floor top plate 252, in that they are designed to permit the lateral movement of
wall portions 200s-2 and 200s-4 relative to floor portions 300a and 300b. A more detailed
description of these sealing structures is set forth in PCT Patent Application No.
PCT/US21/56415, entitled "Enclosure Component Sealing Systems," filed on October 25,
2021 and having the same inventors as the present application, for example in CJICJI 0136-
0147 and in connection with Figure 17 thereof. The contents of that PCT Patent
Application No. PCT/US21/56415, entitled "Enclosure Component Sealing Systems," filed
on October 25, 2021 and having the same inventors as this disclosure, are incorporated by
reference as if fully set forth herein, particularly including the wall end interlock A 262 and
floor top interlock 261 described for example at CJ{CJ{ 0136-0147 and in connection with
Figure 17 thereof.

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 WO 2022/231675 PCT/0S2022/014224

[0060] After the fasteners are driven into the toe screw housings 288, the housings can be
masked from view by placing an interior baseboard 140 of an appropriate length over the
toe screw housings, as shown in Figure lOA. The size of interior baseboard 288 can be
adjusted prior to installation to accommodate flooring finishes of different types. For this
reason, the interior face 142 is provided with a first elongate linear notch 149 (see Figures
9B, 9C) above bottom edge 144 a sufficient distance to indicate the cut line for
accommodating thin flooring, such as floor tiles, and a second elongate linear notch 139
(see Figures 9B, 9C), above notch 149 a sufficient distance to indicate the cut line for
accommodating thicker flooring, such as hardwood flooring.

[0061] In use, the hook ledge 145 of interior baseboard 140 engages the bevel edge 297 of
the toe screw housings 288 positioned along the bottom of the wall component 200, which
thus facilitates the rapid and accurate placement of interior baseboard 140. The interior
baseboard 140 can be secured in place by providing for example hook-and-loop fasteners,
or adhesive material, in the fastening recess 138 of the interior baseboard 140. Toe screw
housings 288 and interior baseboard 140 can be made from aluminum, plastics and the like.
It is preferred to fabricate the toe screw housing 288 and interior baseboard 140 from
foamed polyvinyl chloride (PVC), particularly Celuka foamed PVC.

Floor Component (300)

[0062] Typically, structure 150 will utilize one floor component 300; thus floor component
300 generally is the full floor of structure 150.

A. General Description

[0063] Floor component 300 has a generally rectangular perimeter. Figures 4 and 5 depict
edge-on views of floor component 300 in accordance with the present inventions. The
perimeter of floor component 300 is defined by first longitudinal floor edge 117, first
transverse floor edge 120, second longitudinal floor edge 119 and second transverse floor
edge 118. In particular, (a) first longitudinal floor edge 117, (b) first transverse floor edge
120, (c) second longitudinal floor edge 119 and (d) second transverse floor edge 118
generally coincide with (i.e., underlie) (w) first longitudinal edge 106, (x) first transverse
edge 108, (y) second longitudinal edge 116 and (z) second transverse edge 110,
respectively, of structure 150.

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 WO 2022/231675 PCT/0S2022/014224

[0064] The length and width of floor component 300 can vary in accordance with
design preference. In the particular embodiment of structure 150 depicted in Figures 2, 4
and 5, floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).

[0065] Floor component 300 and its constituent elements are generally designed and
dimensioned in thickness and in other respects to accommodate the particular loads to
which floor component 300 may be subject. It is preferred that floor component 300 utilize
a multi-layered, laminate design, such as that described in connection with Figure 7. In the
embodiment shown in Figures 4 and 5, the bottom-most surface of floor component 300
comprises sheet metal layer 205 of first structural layer 210, with sheet metal layer 205
being 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick. Above sheet
metal layer 205 there are provided foam panels 214 of foam panel layer 213. In the
embodiments shown in Figures 4 and 5, foam panels 214 are EPS foam for example
approximately 7.125 inches thick. Above foam panel layer 213 there is provided sheet
metal layer 216 of second structural layer 215, with sheet metal layer 216 being 24 gauge
galvanized steel approximately 0.022 - 0.028 inch thick. Above sheet metal layer 216 of
second structural layer 215, there are provided building panels 219 of protective layer 218,
with building panels 219 being MgO board approximately 0.25 inch (6 mm) thick.

[0066] The perimeter of each floor component 300 is generally provided with exterior
edge reinforcement. As exterior edge reinforcement for the embodiments of floor
component 300 shown in Figures 4 and 5, a first footing beam 320 (visible edge-on in
Figure 4) is positioned at the first longitudinal floor edge 117 of floor component 300, a
second footing beam 320 (visible edge-on in Figure 5) is positioned at the second
transverse floor edge 118 of floor component 300, a third footing beam 320 (visible edge-
on in Figure 5) is positioned at the first transverse floor edge 120 of floor component 300,
and a fourth footing beam 320 (visible edge-on in Figure 4) is positioned at the second
longitudinal floor edge 119 of floor component 300. In the case of floor component 300,
the exterior edge reinforcement provided by footing beams 320 assists in resisting vertical
loads and transferring such loads to any roof component 400 thereunder and then to
underlying wall components 200, and/or to the foundation of the finished structure 150, in
addition to protecting the edges of foam panel material. In the embodiment shown in
Figures 1 through 6, the exterior edge reinforcement provided by footing beams 420 of
floor component 300 is fabricated from laminated strand lumber board 7.125" deep and
1.5" thick.

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 WO 2022/231675 PCT/0S2022/014224

B. Floor Partitioning

[0067] The floor component 300 is partitioned into floor portion 300a and floor portion
300b. Figure 2 shows flow portions 300a and 300b in plan view, and Figure 4 shows floor
portions 400a and 400b in section view, edge-on.

[0068] Each of the floor portions 300a and 300b is a planar generally rectangular structure,
with floor portion 300a adjoining floor portion 300b. Interior edge 301a of floor portion
300a abuts interior edge 301b of floor portion 300b, as shown in Figure 4. As interior edge
reinforcement, a reinforcing board 307 is positioned in floor portion 300a adjacent interior
edge 301a, and a reinforcing board is positioned in floor portion 300b adjacent interior edge
301b. In the embodiment show in in Figures I through 5, the interior edge reinforcement
provided by reinforcing boards 307 is made of laminated strand lumber laminated strand
lumber board 7.125" deep and 1.5" thick.

[0069] Referring to structure 150 shown in Figures 2 and 4, floor portion 300a is fixed in
position relative to first wall portion 200s-l, third wall portion 200s-3 and wall component
200s-R. Floor portion 300a is joined with hinge structures to floor portion 300b, so as to
permit floor portion 300b to pivot through approximately ninety degrees (90°) of arc about
a horizontal axis 305, located proximate the top surface of floor component 300, between a
fully folded position, where floor portion 300b is vertically oriented as shown in Figure 3,
and the fully unfolded position shown in Figures 2 and 4, where floor portion 300b is
horizontally oriented and co-planar with floor portion 300a. Particular embodiments of
structural members that incorporate hinge structures suitable to join floor portion 300a to
floor portion 300b are described in in U.S. Nonprovisional Patent Application No.
17/527,520 entitled "Folding Beam Systems", filed November 16, 2021 and having the
same inventors as this disclosure. The contents of that U.S. Nonprovisional Patent
Application No. 17/527,520 entitled "Folding Beam Systems", filed November 16, 2021
and having the same inventors as this disclosure, is incorporated by reference as if fully set
forth herein, particularly the description of the hinged load transfer components set forth
for example in CJ{CJ{ 0074-0089 and in Figures 8A-13E thereof, as well as the description of
the associated end hinge assemblies set forth for example in CJ{CJ{ 0090-0093 and in Figures
14A- 14B thereof.

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Roof Component (400)

[0070] Typically, structure 150 will utilize one roof component 400; thus roof component
400 generally is the full roof of structure 150.

A. General Description

[0071] Roof component 400 has a generally rectangular perimeter. Figures 1, 4 and 5
depict roof component 400 in accordance with the present inventions. The perimeter of
roof component 400 is defined by first longitudinal roof edge 406, first transverse roof
edge 408, second longitudinal roof edge 416 and second transverse roof edge 410. In
particular,
(a) first longitudinal roof edge 406, (b) first transverse roof edge 408, (c) second
longitudinal roof edge 416 and (d) second transverse roof edge 410 of roof component 400
generally coincide with (i.e., overlie) (w) first longitudinal edge 106, (x) first transverse
edge 108, (y) second longitudinal edge 116 and (z) second transverse edge 110,
respectively, of structure 150.

[0072] The length and width of roof component 400 can vary in accordance with design
preference. In the particular embodiment of structure 150 depicted in Figures 1, 4 and 5,
the length and width of roof component 400 approximates the length and width of floor
component 300.

[0073] Roof component 400 and its constituent elements are generally designed and
dimensioned in thickness and in other respects to accommodate the particular loads to
which roof component 400 may be subject. It is preferred that roof component 400 utilize a
multi-layered, laminate design, such as that described in connection with Figure 7. In the
embodiment shown in Figures 4 and 5, the top-most surface of roof component 400
comprises sheet metal layer 205 of first structural layer 210, with sheet metal layer 205
being 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick. Below sheet metal
layer 205 there are provided foam panels 214 of foam panel layer 213, with foam panels
214 in the embodiment shown in Figures 4 and 5 being EPS foam for example
approximately 7.125 inches thick. Below foam panel layer 213 there is provided sheet
metal layer 216 of second structural layer 215, with sheet metal layer 216 being 24 gauge
galvanized steel approximately 0.022 - 0.028 inch thick. Below sheet metal layer 216 of
second structural layer 215, there are provided building panels 219 of protective layer 218,
with building panels 219 being MgO board approximately 0.25 inch (6 mm) thick.

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[0074] The perimeter of roof component 400 is generally provided with exterior edge
reinforcement. As exterior edge reinforcement for the embodiment of roof component 400
shown in Figures 4 and 5, a first shoulder beam 435 (visible edge-on in Figure 4) is
positioned at the first longitudinal roof edge 406 of roof component 400, a second shoulder
beam 435 (visible edge-on in Figure 5) is positioned at the first transverse roof edge 408 of
roof component 400, a third shoulder beam 435 (visible edge-on in Figure 5) is positioned
at the second transverse roof edge 410 of roof component 400, and a fourth shoulder beam
435 (visible edge-on in Figure 4) is positioned at the second longitudinal roof edge 416 of
roof component 400. In addition to protecting the exterior edges of foam panel material, the
exterior edge reinforcement provided by shoulder beams 435 assists in resisting vertical
loads and transferring such loads to lower floors through underlying wall components 200
supporting roof component 400, and then to the foundation of the structure 150. Such
exterior edge reinforcement can also provide a region for fastening like regions of abutting
enclosure components 155 (underlying and any overlying). Shoulder beams 435 of roof
component 400 can be fabricated from laminated strand lumber board 7.125" deep and 1.5"
thick.

B. Roof Partitioning

[0075] The roof component 400 of structure 150 is partitioned into roof portions 400a,
400b and 400c. Figure 1 shows roof portions 400a, 400b and 400c in perspective view, and
Figure 4 shows roof portions 400a, 400b and 400c in section view, edge-on.

[0076] Each of the roof portions 400a, 400b and 400c is a planar generally rectangular
structure, with roof portion 400a adjoining roof portion 400b, and roof portion 400b
adjoining roof portion 400c. Interior edge 412c of roof component 400c abuts a first
interior edge 412b of roof component 400b, as shown in Figure 4. For interior edge
reinforcement, a reinforcing board 437 is positioned adjacent interior edge 412c, and a
reinforcing board 437 is positioned against first interior edge 412b. Interior edge 412a of
roof portion 400a abuts a second interior edge 412b of roof portion 400b, as shown in
Figure 4. For interior edge reinforcement, a reinforcing board 437 is positioned adjacent
interior edge 412a, and a reinforcing board 437 is positioned against second interior edge
412b. In the embodiment shown in Figures 1 through 5, the interior edge reinforcement
provided by reinforcing boards 437 of roof component 400 is laminated strand lumber
board 7.125" deep and 1.5" thick..

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 WO 2022/231675 PCT/0S2022/014224

[0077] In the shipping module 100 shown in Figure 3, roof portions 400a, 400b and 400c
preferably are accordion folded (stacked), with roof component 400b stacked on top of roof
component 400a, and roof component 400c stacked on top of the roof component 400b.
Referring to structure 150 shown in Figure 4, roof portion 400a is fixed in position relative
to first wall portion 200s- l, third wall portion 200s-3 and wall component 200R. Thus to
realize the accordion folded configuration shown in Figure 3 roof portion 400a is joined to
roof portion 400b with hinge structures provided between interior edge 412a of roof portion
400a and second interior edge 412b of roof portion 400b. Such hinge structures are adapted
to permit roof portion 400b to pivot through up to one hundred and eighty degrees (180°) of
arc about a horizontal axis 405a, located proximate the top of roof component 400 and
shown in Figure 4, between the roof fully folded position shown in Figure 3, where roof
portion 400b lies stacked flat against roof portion 400a, and the fully unfolded position
shown in Figure 4. In turn, roof portion 400b is joined to roof portion 400c with hinge
structures provided between first interior edge 412b of roof portion 400b and interior edge
412c of roof portion 400c. Such hinge structures are adapted to permit roof portion 400c to
pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis
405b, located proximate the bottom of roof component 400 and shown in Figure 4, between
the folded position shown in Figure 3, where roof portion 400c lies stacked flat against roof
portion 400b (when roof portion 400b is positioned to lie flat against roof portion 400a),
and the fully unfolded position shown in Figure 4.

[0078] Particular embodiments of structural members, which also incorporate hinge

structures suitable for joining roof portion 400a to roof portion 400b, and for joining roof
portion 400b to roof portion 400c, are described in in U.S. Nonprovisional Patent
Application No. 17/527,520 entitled "Folding Beam Systems", filed November 16, 2021
and having the same inventors as this disclosure. The contents of that U.S. Nonprovisional
Patent Application No. 17/527,520 entitled "Folding Beam Systems", filed November 16,
2021 and having the same inventors as this disclosure, is incorporated by reference as if
fully set forth herein, particularly the description of the load transfer components set forth
for example in CJ{CJ{ 0104-0126 and in Figures 15A-24A thereof, as well as the description
of the associated end hinge assemblies set forth for example in CJ{CJ{ 0127-0132 and in
Figures 24B and 25A-25D thereof.

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Enclosure Component Manufacture

[0079] For enclosure components 155 utilizing the multi-layered, laminate design disclosed
herein in reference to Figure 7, the metal sheets 206 and 217 that can be used to form first
structural layer 210 and second structural layer 215 respectively can be entirely flat and
juxtaposed in a simple abutting relationship. Optionally, metal sheets 206 and 217 can be
provided with edge structures that facilitate placement of sheets and panels during
manufacture.

[0080] Particular edge structure designs for metal sheets 206 and 217 are described in U.S.
Nonprovisional Patent Application No. 17/504,883 entitled "Sheet/Panel Design for
Enclosure Component Manufacture," having the same inventors as the inventions described
herein and filed on October 19, 2021. The contents of U.S. Nonprovisional Patent
Application No. 17/504,883 entitled "Sheet/Panel Design for Enclosure Component
Manufacture," having the same inventors as the inventions described herein and filed on
October 19, 2021, are incorporated by reference as if fully set forth herein, particularly
including the exterior and interior edge structure designs described for example at CJICJI
00187- 00205 and 00212 and in Figures 8, 9A-9C, 23A-23J and 24A-24B thereof.

[0081] A facility suitable for the manufacture of enclosure components 155, as well as
exemplary manufacturing steps, are also described in U.S. Nonprovisional Patent
Application No. 17/504,883 entitled "Sheet/Panel Design for Enclosure Component
Manufacture," having the same inventors as the inventions described herein and filed on
October 19, 2021. The contents of U.S. Nonprovisional Patent Application No. 17/504,883
entitled "Sheet/Panel Design for Enclosure Component Manufacture," having the same
inventors as the inventions described herein and filed on October 19, 2021, are
incorporated by reference as if fully set forth herein, particularly including the facility
suitable for manufacturing the enclosure components 155 of the present invention, as well
as exemplary manufacturing steps, described for example at CJ{CJ{ 00178-00186 and 00206-
00222, and in Figures 22, 23A-23J and 24A-24B.

Fixed Space Portion Build-Out and Finishing

[0082] Referring to Figures 2 and lOA-lOC, structure 150 includes a fixed space portion
102 defined by roof component 400a (shown in Figure 3), floor component 300a, wall
component 200R, wall portion 200s- l and wall portion 200s-3. (Fixed space portion 102 is
also shown edge-on in the shipping module 100 depicted in Figure 3). It is preferred that

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the fixed space portion 102 be fitted out during manufacture with internal components,
such as kitchens, bathrooms, closets, storage areas, corridors, etc., so as to be in a relatively
finished state prior to shipment of shipping module 100.

[0083] For example, interior partition walls as desired can be put into fixed space portion
102 during manufacture. Referring to Figures 2 and lOA-lOC, there is shown a
longitudinal partition wall 126 and a transverse partition wall 127. Partition walls 126 and
127 each can comprise a foam panel layer, for example three inches (3") thick, with
building panels such as magnesium oxide (MgO) board approximately 0.25 inch (6 mm)
thick fastened to each face of the foam panel using a suitable adhesive, preferably a
polyurethane based construction adhesive.

[0084] As shown for example in Figure 1 lA, a first vertical edge of longitudinal partition
wall 126 abuts wall portion 200s- l, and a first vertical edge of transverse partition wall 127
abuts wall component 200R. The second vertical edge of transverse wall portion 127 abuts
the longitudinal partition wall 126 proximate to the latter's second vertical edge, such that
partition walls 126 and 127, with wall component 200R and wall portion 200s-l, form a
rectangular enclosed area that, in the embodiment shown in Figures 2 and 1 lA-1lC, is a
bath room 128. In the embodiment shown, bath room 128 is fitted out during manufacture
to include a shower enclosure, a toilet and a wash sink.

[0085] The open area between transverse partition wall 127 and wall portion 200s-3 in the
embodiment shown in Figures 2 and 1 lA-1lC is a kitchen area 129. In the embodiment
shown in Figures 1 lA-11C, kitchen area 129 is fitted out during manufacture to include
cabinets, countertops and cooking facilities.

[0086] Also, in the embodiment shown in Figures 1 and 2, wall components 200 are fitted
during manufacture and prior to shipment with all necessary door and window assemblies,
with the enclosure components 155 being pre-wired for electrical needs.

[0087] Carrying out the foregoing steps prior to shipment permits the builder, in effect, to
erect a largely finished structure simply by "unfolding" (deploying) the positioned
components of shipping module 100.

Enclosure Component Relationships and Assembly for Transport

[0088] It is preferred that there be a specific dimensional relationship among enclosure

components 155.

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 WO 2022/231675 PCT/0S2022/014224

[0089] Figure 2 shows a top schematic view of structure 150 shown in Figure 1, and
includes a geometrical orthogonal grid for clarity of explaining the preferred dimensional
relationships among its enclosure components 155. The basic length used for dimensioning
is indicated as "E" in Figure 2; the orthogonal grid overlaid in Figure 2 is 8E long and 8E
wide; notably, the entire structure 150 preferably is bounded by this 8E by 8E orthogonal
grid.

[0090] Roof portions 400a, 400b and 400c each can be identically dimensioned in the
transverse direction. Alternatively, referring to Figure 3, roof portion 400c can be
dimensioned to be larger than either of roof portion 400a and roof portion 400b in the
transverse direction to reduce the chances of binding during the unfolding of roof portions
400b, 400c. Further specifics on dimensioning roof portion 400c in the foregoing manner
are described in U.S. Nonprovisional Application No. 17/569,962, entitled "Improved
Folding Roof Component," filed on January 6, 2022. In addition, as described in U.S.
Nonprovisional Patent Application No. 16/786,315, entitled "Equipment and Methods for
Erecting a Transportable Foldable Building Structure," filed on February 10, 2020 and now
U.S. Patent No. 11,220,816, as well as in U.S. Nonprovisional Application No. 17/569,962
mentioned above, friction-reducing components can be used to facilitate unfolding roof
component 400, such as by positioning a first wheel caster at the leading edge of roof
portion 400c proximate to the corner of roof portion 400c that is supported by wall portion
200s-2 as roof portion 400c is deployed, and by positioning a second similar wheel caster at
the leading edge of roof portion 400c proximate to the corner of roof portion 400c that is
supported by wall portion 200s-4 as roof portion 400c is deployed.

[0091] In Figure 2, the four wall components 200 are each approximately 8E long, and
each of roof portions 400a and 400b is approximately 8E long and 2.5E wide. Roof portion
400c is approximately 8E long and 2.9E wide. In Figures 2 and 3, each of floor components
300a and 300b is 8H long; whereas floor component 300a is just over 3E wide and floor
component 300b is just under 5E wide.

[0092] As shown in Figure 2, fourth wall portion 200s-4 is folded inward and positioned
generally against fixed space portion 102, and second wall portion 200s-2 is folded inward
and positioned generally against fourth wall portion 200s-4 (wall portions 200s-2 and 200s-
4 are respectively identified in Figure 2 as portions 200s-2f and 200s-4f when so folded and
positioned). The three roof components 400a, 400b and 400c are shown unfolded in Figure
1 and shown folded (stacked) in Figure 3, with roof component 400b stacked on top of roof

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component 400a, and roof component 400c stacked on top of the roof component 400b.
Wall component 200P, shown in Figures 2 and 3, is pivotally secured to floor portion
300b at the location of axis 105, and is vertically positioned against the outside of wall
portions 200s-2 and 200s-4. In tum, floor portion 300b is vertically positioned proximate
fixed space portion 102, with wall component 200P pending from floor portion 300b
between floor portion 300b and wall portions 200s-2 and 200s-4.

[0093] Sizing the enclosure components 155 of structure 150 according to the dimensional
relationships disclosed above yields a compact shipping module 100, as can be seen from
the figures. Thus shipping module 100 depicted in Figure 3, when dimensioned according
to the relationships disclosed herein using an "E" dimension (see Figure 2) of
approximately 28.625 inches (72.7 cm), and when its components are stacked and
positioned as shown in Figure 3, has an overall length of approximately 19 feet (5.79 m),
an overall width of approximately 8.5 feet (2.59 meters) and an overall height of
approximately 12.7 feet (3.87 meters). These overall dimensions are less than a typical
shipping container.

[0094] Each of the wall, floor and roof components 200, 300 and 400, and/or the portions
thereof, can be sheathed in protective film 177 during fabrication and prior to forming the
shipping module 100. Alternatively or in addition, the entire shipping module 100 can be
sheathed in a protective film. Such protective films can remain in place until after the
shipping module 100 is at the construction site, and then removed as required to facilitate
enclosure component deployment and finishing.

Shipping Module Transport

[0095] The shipping module 100 is shipped to the building site by appropriate transport
means. One such transport means is disclosed in U.S. Nonprovisional Application No.
16/143,628, filed September 27, 2018 and now U.S. Patent No. 11,007,921, issued May 18,
2021; the contents of that U.S. Nonprovisional Application No. 16/143,628, filed
September 27, 2018 are incorporated by reference as if fully set forth herein, particularly as
found at paragraphs 0020-0035 and in Figures lA-2D thereof. As an alternative transport
means, shipping module 100 can be shipped to the building site by means of a conventional
truck trailer or a low bed trailer (also referred to as a lowboy trailer), and in the case of
over-the water shipments, by ship.

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Structure Deployment and Finishing

[0096] At the building site, shipping module I00 is positioned over its desired location,
such as over a prepared foundation; for example, a poured concrete slab, a poured concrete
or cinder block foundation, sleeper beams or concrete posts or columns. This can be
accomplished by using a crane, either to lift shipping module I00 from its transport and
move it to the desired location, or by positioning the transport means over the desired
location, lifting shipping module I00, then moving the transport means from the desired
location, and then lowering shipping module I00 to a rest state at the desired location.
Particularly suitable equipment and techniques for facilitating the positioning of a shipping
module 100 at the desired location are disclosed in U.S. Nonprovisional Patent Application
No. 16/786,315, entitled "Equipment and Methods for Erecting a Transportable Foldable
Building Structure," and filed on February 10, 2020, now U.S. Patent No. 11,220,816. The
contents of that U.S. Nonprovisional Patent Application No. 16/786,315, entitled
"Equipment and Methods for Erecting a Transportable Foldable Building Structure," and
filed on February 10, 2020, are incorporated by reference as if fully set forth herein,
particularly including the equipment and techniques described for example at CJ{CJ{ 126-128
and in connection with Figures llA and llB thereof.

[0097] Following positioning of shipping module I00 at the building site, the appropriate
portions of wall, floor and roof components 200, 300 and 400 are "unfolded" (i.e.,
deployed) to yield structure 150. Unfolding occurs in the following sequence: (1) floor
portion 300b is pivotally rotated about horizontal axis 305 (shown in Figures 3 and 4) to an
unfolded position, (2) wall component 200P is pivotally rotated about horizontal axis 105
(the general location of which is shown in Figure 3) to an unfolded position, (3) wall
portions 200s-2 and 200s-4 are pivotally rotated about vertical axes 192 and 194 (shown in
Figure 2) respectively to unfolded positions, and (4) roof portions 400b and 400c are
pivotally rotated about horizontal axes 405a and 405b (shown in Figures 3 and 4)
respectively to unfolded positions.

[0098] A mobile crane can be used to assist in the deployment of certain of the enclosure
components 155, specifically roof portions 400b and 400c, floor portion 300b, as well as the
wall component 200P pivotally secured to floor portion 300b. Alternatively, particularly
suitable equipment and techniques for facilitating the deployment of enclosure components
155 are disclosed in U.S. Nonprovisional Patent Application No. 16/786,315, entitled
"Equipment and Methods for Erecting a Transportable Foldable Building Structure," and

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filed on February 10, 2020, now U.S. Patent No. 11,220,816. The contents of that U.S.
Nonprovisional Patent Application No. 16/786,315, entitled "Equipment and Methods for
Erecting a Transportable Foldable Building Structure," and filed on February 10, 2020, are
incorporated by reference as if fully set forth herein, particularly including the equipment
and techniques described for example at CJ{CJ{ 132-145 and depicted in Figures 12A-14B
thereof.

[0099] After unfolding, the enclosure components 155 are secured together to finish the
structure 150 that is shown in Figure 1. If any temporary hinge structures have been
utilized, then these temporary hinge structures can be removed if desired and the enclosure
components 155 can be secured together. During or after unfolding and securing of the
enclosure components 155, any remaining finishing operations are performed, such as
addition of roofing material, and making hook-ups to electrical, fresh water and sewer lines
to complete structure 150, as relevant here.

[00100] This disclosure should be understood to include (as illustrative and not limiting)
the subject matter set forth in the following numbered clauses:
Clause 1. A toe screw housing for securing abutting enclosure components together,
compnsmg:
a bearing plate with a planar interior face, a planar exterior face and a beveled upper
edge beveled at a non-perpendicular first angle relative to the exterior face;
a toe screw well joined to and extending away from the interior face and including a
fastener shelf;
a toe screw support joined to the interior face, and joined to and extending away from
the fastener shelf, the toe screw support distal from the fastener shelf including a planar
support surface oriented perpendicular to the interior face; and
a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior
face of the bearing plate.
Clause 2. The toe screw housing of clause 1, further including a groove formed in the
support surface oriented parallel to the interior face.
Clause 3. The toe screw housing of either of clause 1 or clause 2, wherein the second
angle is in the range of forty-five degrees (45°) to seventy degrees (70°).
Clause 4. The toe screw housing of any one of clause 1, 2 or 3, where the second
angle is sixty degrees (60°).

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Clause 5. The toe screw housing of any one of clause 1, 2, 3 or 4, where the first
angle is less than forty-five degrees (45°).
Clause 6. The toe screw housing of any one of clause 1, 2, 3, 4 or 5, where the first
angle is twenty degrees (20°).
Clause 7. A baseboard for masking a toe screw bearing plate having a beveled
upper edge, comprising:
a planar elongate member having an elongate interior face, an elongate top edge and
an elongate bottom edge;
an elongate hook ledge joined to the top edge of the base board forming a wedge
shaped angled slot that is oriented to be open in the direction of the bottom edge, the wedge
shaped angled slot configured to be positioned over the beveled upper edge of the bearing
plate;
an elongate linear first step positioned on the interior face below the angled slot to
form an elongate first recess on the interior face configured to receive the toe screw bearing
plate; and
an elongate second step positioned on the interior face below the elongate first step to
form an elongate second recess on the interior face.
Clause 8. A baseboard as in clause 7, further comprising a first elongate linear
notch in the second step a first select distance above the bottom edge.
Clause 9. A baseboard as in either of clause 7 or clause 8, further comprising a
second elongate linear notch in the second step a second select distance above the bottom
edge that is greater than the first select distance.
Clause 10. A system for securing abutting enclosure components together,
compnsmg:
(a) a toe screw housing that includes:
(i) a bearing plate with a planar interior face, a planar exterior face and a
beveled upper edge beveled at a non-perpendicular first angle relative to the exterior
face;
(ii) a toe screw well joined to and extending away from the interior face
and including a fastener shelf;
(iii) a toe screw support joined to the interior face, and joined to and extending away
from the fastener shelf, the toe screw support distal from the fastener shelf including a
planar support surface oriented perpendicular to the interior face; and

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(iv) a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior
face of the bearing plate; and
(b) a planar elongate base board having an elongate top edge and an elongate
bottom edge and including;
(i) an elongate hook ledge joined to the top edge of the base board, the hook
ledge positioned over the beveled upper edge of the bearing plate; and
(ii) an elongate linear first step positioned on the interior face below the angled slot
to form an elongate first recess on the interior face in which is positioned the toe screw
bearing plate.
Clause 11. The system of claim I0, further comprising (iii) an elongate second step
positioned on the interior face of the base board below the elongate first step to form an
elongate second recess on the interior face.
Clause 12. A wall component comprising:
(a) a foam panel layer having a first face and an opposing second face;
(b) a metal sheet layer having a first face, an opposing second face, with the first
face of the metal sheet layer being bonded to the opposing second face of the foam panel
layer; and
(c) a protective layer having a first face, an opposing second face, with the first
face of the protective layer being bonded to the opposing second face of the sheet metal
layer;
(d) an elongate external edge reinforcement abutting the foam panel layer;
(e) a plurality of toe screw housings, each of the plurality of toe screw
housings compnsmg:
(i) a bearing plate with a planar interior face, a planar exterior face and a
beveled upper edge beveled at a non-perpendicular first angle relative to the exterior
face;
(ii) a toe screw well joined to and extending away from the interior face
and including a fastener shelf;
(iii) a toe screw support joined to the interior face, and joined to and extending away
from the fastener shelf, the toe screw support distal from the fastener shelf including a
planar support surface oriented perpendicular to the interior face; and
(iv) a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior

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face of the bearing plate; and

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(f) the toe screw well and toe screw support of each toe screw housing positioned in a
respective one of a plurality of spaced-apart apertures passing through the protective layer
and the metal sheet layer, and in a respective one of a plurality of corresponding cavities
formed in the foam panel layer, with the planar support surface of the toe screw support of
each of the plurality of toe screw housings positioned against the external edge reinforcement
and with the interior face of the bearing plate positioned against the protective layer
Clause 13. A folded building structure transportable to a site at which the folded
building structure is to be erected, comprising:
a fixed space portion defined by (i) a first floor portion having an edge reinforcement
along a first outside edge and an edge reinforcement segment along an adjacent second
outside edge, (ii) a first wall component having an edge reinforcement along a first bottom
edge positioned on the first floor portion proximate the first outside edge, and (iii) a planar
fixed wall portion of a second wall component having an edge reinforcement segment along a
second bottom edge positioned on the first floor portion proximate the second outside edge;
a second floor portion vertically positioned in a second floor portion folded position
opposite to the first wall component and pivotally connected to the first floor portion to
permit the second floor portion to pivot, about a first horizontal axis relative to the first floor
portion, from the second floor portion folded position to a second floor portion unfolded
position, the second floor portion having an edge reinforcement along a third outside edge
distal from the first horizontal axis and an edge reinforcement segment along an adjacent
fourth outside edge;
a third wall component vertically positioned in a third wall component folded position
against the second floor portion, the third wall component pivotally connected to the second
floor portion to permit the third wall portion to pivot, about a second horizontal axis relative
to the second floor portion, from the third wall component folded position to a third wall
component unfolded position, the third wall component having an edge reinforcement along
a third bottom edge positioned on the second floor portion proximate to the third outside edge
when the second floor portion is in the second floor portion unfolded position and the third
wall component is in the third wall component unfolded position;
the second wall component additionally including a planar pivoting wall portion
having an edge reinforcement segment along a fourth bottom edge, the pivoting wall
portion
(i) disposed in a pivoting portion folded position proximate the fixed space portion, and (ii)
pivotally connected to the fixed wall portion of the second wall component to permit the

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pivoting wall portion to pivot, about a vertical axis relative to the fixed wall portion of the

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second wall component, from the pivoting portion folded position to a pivoting portion
unfolded position in which at least a portion of the fourth bottom edge is positioned on the
second floor portion proximate to the fourth outside edge when the second floor portion is in
the second floor portion unfolded position and the pivoting wall portion is in the pivoting
portion unfolded position;
a first plurality of toe screw housings having a spaced-apart relationship, each of the
first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face,
a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle
relative to the exterior face, (ii) a toe screw well joined to and extending away from the
interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face,
and joined to and extending away from the fastener shelf, the toe screw support distal from
the fastener shelf including a planar support surface oriented perpendicular to the interior
face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior face
of the bearing plate; and
the toe screw well and toe screw support of at least a first of the first plurality of toe
screw housings positioned with the interior face of its bearing plate against an inside
surface of the pivoting wall portion and with its support surface against the edge
reinforcement segment along the fourth bottom edge of the pivoting wall portion.
Clause 14. A folded building structure as in clause 13, further comprising a second
plurality of toe screw housings having a spaced-apart relationship, each of the second
plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face, a
planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle
relative to the exterior face, (ii) a toe screw well joined to and extending away from the
interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face,
and joined to and extending away from the fastener shelf, the toe screw support distal from
the fastener shelf including a planar support surface oriented perpendicular to the interior
face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior face
of the bearing plate; and
the toe screw well and toe screw support of each of the second plurality of toe screw
housings positioned with the interior face of its bearing plate against an inside surface of the
third wall component and with its support surface against the edge reinforcement along the
third bottom edge of the third wall component.

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Clause 15. A folded building structure as in either of clause 13 or clause 14, further
comprising a third plurality of toe screw housings having a spaced-apart relationship, each of
the third plurality of toe screw housings comprising: (i) a bearing plate with a planar interior
face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular first
angle relative to the exterior face, (ii) a toe screw well joined to and extending away from the
interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face,
and joined to and extending away from the fastener shelf, the toe screw support distal from
the fastener shelf including a planar support surface oriented perpendicular to the interior
face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior face
of the bearing plate;
the toe screw well and toe screw support of each of the third plurality of toe screw
housings positioned with the interior face of its bearing plate against an inside surface of the
first wall component and with its support surface against the edge reinforcement along the
first bottom edge of the first wall component; and
a first fastener positioned within at least one of the third plurality of toe screw
housings, the first fastener comprising a head in pressing contact with the fastener shelf
thereof, and a shank passing through the toe screw well thereof, through the edge
reinforcement along the first bottom edge of the first wall component and into the edge
reinforcement along the first outside edge of the first floor portion.
Clause 16. A folded building structure as in any one of clause 13. 14 or 15, further
comprising a fourth plurality of toe screw housings having a spaced-apart relationship, each
of the fourth plurality of toe screw housings comprising: (i) a bearing plate with a planar
interior face, a planar exterior face and a beveled upper edge beveled at a non-perpendicular
first angle relative to the exterior face, (ii) a toe screw well joined to and extending away
from the interior face and including a fastener shelf, (iii) a toe screw support joined to the
interior face, and joined to and extending away from the fastener shelf, the toe screw support
distal from the fastener shelf including a planar support surface oriented perpendicular to the
interior face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support
and the support surface and inclined at a non-perpendicular second angle relative to the
interior face of the bearing plate;
the toe screw well and toe screw support of each of the fourth plurality of toe screw
housings positioned with the interior face of its bearing plate against an inside surface of the

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fixed wall portion and with its support surface against the edge reinforcement segment along
the second bottom edge of the fixed wall portion; and
a second fastener positioned within at least one of the fourth plurality of toe screw
housings, the second fastener comprising a head in pressing contact with the fastener shelf
thereof, and a shank passing through the toe screw well thereof, through the edge
reinforcement segment along the second bottom edge of the fixed wall portion and into the
edge reinforcement segment along the second outside edge of the first floor portion.
Clause 17. A building comprising:
an interior region defined by (i) a floor portion having an edge reinforcement along a
first outside edge and an edge reinforcement segment along an adjacent second outside edge,
(ii) a wall component having an edge reinforcement along a first bottom edge positioned on
the first floor portion proximate the first outside edge, and (iii) a wall portion having an edge
reinforcement segment along a second bottom edge positioned on the first floor portion
proximate the second outside edge;
a first plurality of toe screw housings having a spaced-apart relationship, each of the
first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face,
a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle
relative to the exterior face, (ii) a toe screw well joined to and extending away from the
interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face,
and joined to and extending away from the fastener shelf, the toe screw support distal from
the fastener shelf including a planar support surface oriented perpendicular to the interior
face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior face
of the bearing plate; and
the toe screw well and toe screw support of each of the first plurality of toe screw
housings positioned with the interior face of its bearing plate against an inside surface of the
wall component and with its support surface against the edge reinforcement along the first
bottom edge of the wall component.
Clause 18. The building of clause 17, further comprising a first interior partition wall
abutting one of (i) the inside surface of the wall component and (ii) an inside surface of the
wall portion, and extending perpendicularly therefrom.
Clause 19. The building of clause 18, further comprising a second interior partition
wall abutting the other of the inside surface of the wall component and the inside surface of

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the wall portion and extending perpendicularly therefrom to form a junction with the first
interior partition wall and thereby define an enclosed interior space.
Clause 20. The building of either of clause 18 or clause 19, wherein the first interior
partition wall comprises:
(a) a foam panel layer having a first face and an opposing second face;
(b) a first protective layer having a first face, an opposing second face, with the
first face of the first protective layer being bonded to the first face of the foam panel layer;
and
(c) a second protective layer having a first face, an opposing second face, with the
first face of the second protective layer being bonded to the opposing second face of the
foam panel layer.
Clause 21. The building of clause 19, wherein the second interior partition wall
compnses:
(a) a foam panel layer having a first face and an opposing second face;
(b) a first protective layer having a first face, an opposing second face, with the
first face of the first protective layer being bonded to the first face of the foam panel layer;
and
(c) a second protective layer having a first face, an opposing second face, with the
first face of the second protective layer being bonded to the opposing second face of the
foam panel layer.
Clause 22. The building of either of clause 19 or clause 21, wherein the enclosed
interior space includes one or more of a shower enclosure, a toilet and a wash sink.
Clause 23. The building of any one of clause 19, 21 or 22, wherein a portion of the
interior region outside the enclosed interior space includes one or more of a cabinet, a
countertop and a cooking facility.
Clause 24. The building of any one of clauses 17-23, wherein the first wall
component comprises:
(a) a foam panel layer having a first face and an opposing second face;
(b) a metal sheet layer having a first face, an opposing second face, with the first
face of the metal sheet layer being bonded to the opposing second face of the foam panel
layer; and
(c) a protective layer having a first face, an opposing second face that constitutes the
inside surface of the first wall component, with the first face of the protective layer being
bonded to the opposing second face of the sheet metal layer; and

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(d) the edge reinforcement along the first bottom edge of the first wall
component abuts the foam panel layer.

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Clause 25. The folded building structure of clause 15, further comprising a planar
elongate base board having an elongate top edge and an elongate bottom edge, with an
elongate hook ledge joined to the top edge of the base board and positioned over the
beveled upper edge of the bearing plate of at least one of the toe screw housings of the third
plurality of toe screw housings.
Clause 26. The folded building structure of clause 16, further comprising a planar
elongate base board having an elongate top edge and an elongate bottom edge, with an
elongate hook ledge joined to the top edge of the base board and positioned over the beveled
upper edge of the bearing plate of at least one of the toe screw housings of the fourth
plurality of toe screw housings.

[00101] The foregoing detailed description is for illustration only and is not to be deemed
as limiting the inventions disclosed herein, which are defined in the appended claims.

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WHAT IS CLAIMED IS:

1. A toe screw housing for securing abutting enclosure components

together, compnsmg:

a bearing plate with a planar interior face, a planar exterior face and a beveled upper
edge beveled at a non-perpendicular first angle relative to the exterior face;

a toe screw well joined to and extending away from the interior face and including a
fastener shelf;

a toe screw support joined to the interior face, and joined to and extending away from
the fastener shelf, the toe screw support distal from the fastener shelf including a planar
support surface oriented perpendicular to the interior face; and

a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior
face of the bearing plate.

2. The toe screw housing of claim 1, further including a groove formed in the
support surface oriented parallel to the interior face.

3. The toe screw housing of claim 1, wherein the second angle is in the range
of forty-five degrees (45°) to seventy degrees (70°).

4. The toe screw housing of claim 3, where the second angle is sixty degrees
(60°).

5. The toe screw housing of claim 1, where the first angle is less than forty-
five degrees (45°).

6. The toe screw housing of claim 5, where the first angle is twenty degrees
(20°).

7. A baseboard for masking a toe screw bearing plate having a beveled

upper edge, comprising:

a planar elongate member having an elongate interior face, an elongate top edge and
an elongate bottom edge;

an elongate hook ledge joined to the top edge of the base board forming a wedge
shaped angled slot that is oriented to be open in the direction of the bottom edge, the wedge-

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shaped angled slot configured to be positioned over the beveled upper edge of the bearing
plate;

an elongate linear first step positioned on the interior face below the angled slot to
form an elongate first recess on the interior face configured to receive the toe screw bearing
plate; and

an elongate second step positioned on the interior face below the elongate first step to
form an elongate second recess on the interior face.

8. A baseboard as in claim 7, further comprising a first elongate linear notch

in the second step a first select distance above the bottom edge.

9. A baseboard as in claim 8, further comprising a second elongate linear notch

in the second step a second select distance above the bottom edge that is greater than the
first select distance.

10. A system for securing abutting enclosure components together, comprising:

(a) a toe screw housing that includes:

(i) a bearing plate with a planar interior face, a planar exterior face and a
beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face;

(ii) a toe screw well joined to and extending away from the interior face
and including a fastener shelf;

(iii) a toe screw support joined to the interior face, and joined to and extending
away from the fastener shelf, the toe screw support distal from the fastener shelf including
a planar support surface oriented perpendicular to the interior face; and

(iv) a fastener bore passing through the fastener shelf, the toe screw support and
the support surface and inclined at a non-perpendicular second angle relative to the
interior face of the bearing plate; and

(b) a planar elongate base board having an elongate top edge and an
elongate bottom edge and including;

(i) an elongate hook ledge joined to the top edge of the base board, the
hook ledge positioned over the beveled upper edge of the bearing plate; and

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(ii) an elongate linear first step positioned on the interior face below the angled
slot to form an elongate first recess on the interior face in which is positioned the toe
screw bearing plate.

11. The system of claim I0, further comprising (iii) an elongate second step
positioned on the interior face of the base board below the elongate first step to form
an elongate second recess on the interior face.

12. A wall component comprising:

(a) a foam panel layer having a first face and an opposing second face;
(b) a metal sheet layer having a first face, an opposing second face, with the
first face of the metal sheet layer being bonded to the opposing second face of the foam
panel layer; and
(c) a protective layer having a first face, an opposing second face, with the first
face of the protective layer being bonded to the opposing second face of the sheet metal
layer;
(d) an elongate external edge reinforcement abutting the foam panel layer;
(e) a plurality of toe screw housings, each of the plurality of toe screw
housings compnsmg:
(i) a bearing plate with a planar interior face, a planar exterior face and a
beveled upper edge beveled at a non-perpendicular first angle relative to the exterior face;

(ii) a toe screw well joined to and extending away from the interior face
and including a fastener shelf;

(iii) a toe screw support joined to the interior face, and joined to and extending
away from the fastener shelf, the toe screw support distal from the fastener shelf including
a planar support surface oriented perpendicular to the interior face; and

(iv) a fastener bore passing through the fastener shelf, the toe screw support and
the support surface and inclined at a non-perpendicular second angle relative to the
interior face of the bearing plate; and
(f) the toe screw well and toe screw support of each toe screw housing
positioned in a respective one of a plurality of spaced-apart apertures passing through the
protective layer and the metal sheet layer, and in a respective one of a plurality of
corresponding cavities formed in the foam panel layer, with the planar support surface of the
toe screw support of each of the plurality of toe screw housings positioned against the
external edge
41
 WO 2022/231675 PCT/0S2022/014224

reinforcement and with the interior face of the bearing plate positioned against the protective
layer.

13. A folded building structure transportable to a site at which the folded

building structure is to be erected, comprising:

a fixed space portion defined by (i) a first floor portion having an edge reinforcement
along a first outside edge and an edge reinforcement segment along an adjacent second
outside edge, (ii) a first wall component having an edge reinforcement along a first bottom
edge positioned on the first floor portion proximate the first outside edge, and (iii) a planar
fixed wall portion of a second wall component having an edge reinforcement segment along a
second bottom edge positioned on the first floor portion proximate the second outside edge;

a second floor portion vertically positioned in a second floor portion folded position
opposite to the first wall component and pivotally connected to the first floor portion to
permit the second floor portion to pivot, about a first horizontal axis relative to the first floor
portion, from the second floor portion folded position to a second floor portion unfolded
position, the second floor portion having an edge reinforcement along a third outside edge
distal from the first horizontal axis and an edge reinforcement segment along an adjacent
fourth outside edge;

a third wall component vertically positioned in a third wall component folded position
against the second floor portion, the third wall component pivotally connected to the second
floor portion to permit the third wall portion to pivot, about a second horizontal axis relative
to the second floor portion, from the third wall component folded position to a third wall
component unfolded position, the third wall component having an edge reinforcement along
a third bottom edge positioned on the second floor portion proximate to the third outside edge
when the second floor portion is in the second floor portion unfolded position and the third
wall component is in the third wall component unfolded position;

the second wall component additionally including a planar pivoting wall portion
having an edge reinforcement segment along a fourth bottom edge, the pivoting wall
portion
(i) disposed in a pivoting portion folded position proximate the fixed space portion, and (ii)
pivotally connected to the fixed wall portion of the second wall component to permit the
pivoting wall portion to pivot, about a vertical axis relative to the fixed wall portion of the
second wall component, from the pivoting portion folded position to a pivoting portion
unfolded position in which at least a portion of the fourth bottom edge is positioned on the
42
 WO 2022/231675 PCT/0S2022/014224

second floor portion proximate to the fourth outside edge when the second floor portion is in
the second floor portion unfolded position and the pivoting wall portion is in the pivoting
portion unfolded position;

a first plurality of toe screw housings having a spaced-apart relationship, each of the
first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face,
a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle
relative to the exterior face, (ii) a toe screw well joined to and extending away from the
interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face,
and joined to and extending away from the fastener shelf, the toe screw support distal from
the fastener shelf including a planar support surface oriented perpendicular to the interior
face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior face
of the bearing plate; and

the toe screw well and toe screw support of at least a first of the first plurality of toe
screw housings positioned with the interior face of its bearing plate against an inside
surface of the pivoting wall portion and with its support surface against the edge
reinforcement segment along the fourth bottom edge of the pivoting wall portion.

14. A folded building structure as in claim 13, further comprising a second plurality
of toe screw housings having a spaced-apart relationship, each of the second plurality of toe
screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior
face and a beveled upper edge beveled at a non-perpendicular first angle relative to the
exterior face, (ii) a toe screw well joined to and extending away from the interior face and
including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to
and extending away from the fastener shelf, the toe screw support distal from the fastener
shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a
fastener bore passing through the fastener shelf, the toe screw support and the support
surface and inclined at a non-perpendicular second angle relative to the interior face of the
bearing plate; and

the toe screw well and toe screw support of each of the second plurality of toe screw
housings positioned with the interior face of its bearing plate against an inside surface of the
third wall component and with its support surface against the edge reinforcement along the
third bottom edge of the third wall component.

43
 WO 2022/231675 PCT/0S2022/014224

15. A folded building structure as in claim 14, further comprising a third plurality of
toe screw housings having a spaced-apart relationship, each of the third plurality of toe
screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior
face and a beveled upper edge beveled at a non-perpendicular first angle relative to the
exterior face,
(ii) a toe screw well joined to and extending away from the interior face and including a
fastener shelf, (iii) a toe screw support joined to the interior face, and joined to and extending
away from the fastener shelf, the toe screw support distal from the fastener shelf including a
planar support surface oriented perpendicular to the interior face, and (iv) a fastener bore
passing through the fastener shelf, the toe screw support and the support surface and inclined
at a non-perpendicular second angle relative to the interior face of the bearing plate;

the toe screw well and toe screw support of each of the third plurality of toe screw
housings positioned with the interior face of its bearing plate against an inside surface of the
first wall component and with its support surface against the edge reinforcement along the
first bottom edge of the first wall component; and

a first fastener positioned within at least one of the third plurality of toe screw
housings, the first fastener comprising a head in pressing contact with the fastener shelf
thereof, and a shank passing through the toe screw well thereof, through the edge
reinforcement along the first bottom edge of the first wall component and into the edge
reinforcement along the first outside edge of the first floor portion.

16. A folded building structure as in claim 15, further comprising a fourth plurality
of toe screw housings having a spaced-apart relationship, each of the fourth plurality of toe
screw housings comprising: (i) a bearing plate with a planar interior face, a planar exterior
face and a beveled upper edge beveled at a non-perpendicular first angle relative to the
exterior face, (ii) a toe screw well joined to and extending away from the interior face and
including a fastener shelf, (iii) a toe screw support joined to the interior face, and joined to
and extending away from the fastener shelf, the toe screw support distal from the fastener
shelf including a planar support surface oriented perpendicular to the interior face, and (iv) a
fastener bore passing through the fastener shelf, the toe screw support and the support surface
and inclined at a non-perpendicular second angle relative to the interior face of the bearing
plate;

the toe screw well and toe screw support of each of the fourth plurality of toe screw
housings positioned with the interior face of its bearing plate against an inside surface of the

44
 WO 2022/231675 PCT/0S2022/014224

fixed wall portion and with its support surface against the edge reinforcement segment along
the second bottom edge of the fixed wall portion; and

a second fastener positioned within at least one of the fourth plurality of toe screw
housings, the second fastener comprising a head in pressing contact with the fastener shelf
thereof, and a shank passing through the toe screw well thereof, through the edge
reinforcement segment along the second bottom edge of the fixed wall portion and into the
edge reinforcement segment along the second outside edge of the first floor portion.

17. A building comprising:

an interior region defined by (i) a floor portion having an edge reinforcement along a
first outside edge and an edge reinforcement segment along an adjacent second outside edge,
(ii) a wall component having an edge reinforcement along a first bottom edge positioned on
the first floor portion proximate the first outside edge, and (iii) a wall portion having an edge
reinforcement segment along a second bottom edge positioned on the first floor portion
proximate the second outside edge;

a first plurality of toe screw housings having a spaced-apart relationship, each of the
first plurality of toe screw housings comprising: (i) a bearing plate with a planar interior face,
a planar exterior face and a beveled upper edge beveled at a non-perpendicular first angle
relative to the exterior face, (ii) a toe screw well joined to and extending away from the
interior face and including a fastener shelf, (iii) a toe screw support joined to the interior face,
and joined to and extending away from the fastener shelf, the toe screw support distal from
the fastener shelf including a planar support surface oriented perpendicular to the interior
face, and (iv) a fastener bore passing through the fastener shelf, the toe screw support and the
support surface and inclined at a non-perpendicular second angle relative to the interior face
of the bearing plate; and

the toe screw well and toe screw support of each of the first plurality of toe screw
housings positioned with the interior face of its bearing plate against an inside surface of the
wall component and with its support surface against the edge reinforcement along the first
bottom edge of the wall component.

18. The building of claim 17, further comprising a first interior partition wall
abutting one of (i) the inside surface of the wall component and (ii) an inside surface of the
wall portion, and extending perpendicularly therefrom.

45
 WO 2022/231675 PCT/0S2022/014224

19. The building of claim 18, further comprising a second interior partition wall
abutting the other of the inside surface of the wall component and the inside surface of the
wall portion and extending perpendicularly therefrom to form a junction with the first
interior partition wall and thereby define an enclosed interior space.

20. The building of claim 18, wherein the first interior partition wall comprises:

(a) a foam panel layer having a first face and an opposing second face;

(b) a first protective layer having a first face, an opposing second face, with the
first face of the first protective layer being bonded to the first face of the foam panel layer;
and

(c) a second protective layer having a first face, an opposing second face, with the
first face of the second protective layer being bonded to the opposing second face of the
foam panel layer.

21. The building of claim 19, wherein the second interior partition wall comprises:

(a) a foam panel layer having a first face and an opposing second face;

(b) a first protective layer having a first face, an opposing second face, with the
first face of the first protective layer being bonded to the first face of the foam panel layer;
and

(c) a second protective layer having a first face, an opposing second face, with the
first face of the second protective layer being bonded to the opposing second face of the
foam panel layer.

22. The building of claim 19, wherein the enclosed interior space comprises one or
more of a shower enclosure, a toilet and a wash sink.

23. The building of claim 22, wherein a portion of the interior region outside the
enclosed interior space includes one or more of a cabinet, a countertop and a cooking
facility.

24. The building of claim 23, wherein the first wall component comprises:

(a) a foam panel layer having a first face and an opposing second face;

(b) a metal sheet layer having a first face, an opposing second face, with the first
face of the metal sheet layer being bonded to the opposing second face of the foam panel
layer; and

46
 WO 2022/231675 PCT/0S2022/014224

(c) a protective layer having a first face, an opposing second face that constitutes the
inside surface of the first wall component, with the first face of the protective layer being
bonded to the opposing second face of the sheet metal layer; and

(d) the edge reinforcement along the first bottom edge of the first wall
component abuts the foam panel layer.

25. The folded building structure of claim 15, further comprising a planar elongate
base board having an elongate top edge and an elongate bottom edge, with an elongate
hook ledge joined to the top edge of the base board and positioned over the beveled upper
edge of the bearing plate of at least one of the toe screw housings of the third plurality of
toe screw housings.

26. The folded building structure of claim 16, further comprising a planar elongate
base board having an elongate top edge and an elongate bottom edge, with an elongate
hook ledge joined to the top edge of the base board and positioned over the beveled upper
edge of the bearing plate of at least one of the toe screw housings of the fourth plurality of
toe screw housings.

47
 WO 2022/231675

PCT/US2022/014224

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 INTERNATIONAL SEARCH REPORT International application No.

PCT/US 22/14224

A. CLASSIFICATION OF SUBJECT MATTER

IPC- E0481/38, F168 9/00, E04F 15/02, F168 5/02, 823P 11/00, 823P 17/00, E04C 2/284 (2022.01)
CPC - F168 15/0053, F168 15/0023, F168 15/003, F168 2015/0061, F168 43/00, F168 2043/008,
F168 43/02, E048 5/12, F168 12/46, F168 12/44, F168 12/50, E04F 11/108, F168 9/058, F168
9/05, F168 9/00, F168 9/052, E048 1/344, 8328 15/14, 8328 21/047, E04B 1/34357, E04B
2001/34389, E04B 1/343
According to International Patent Classification (!PC) or to both national classification and lPC
B. FIELDS SEARCHED

Minimum documentation searched (classification system followed by classification symbols)

See Search History doi;u1111:mt

Documentation searched other than minimum documentation to the extent that such documents are included in the fields searched
See Search History document

Electronic data base consulted during the international search (name of data base and, where practicable, search terms used)
See Search History document

C. DOCUMENTS CONSIDERED TO BE RELEVANT

Category* Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim No.

X CH 713912 A1 (PROYERUM AG}, 28 December 2018 (28.12.2018), entire document, 7

-y especially Figs 1-2b -
8-9
-A --
10-11

y US 2016/0215508 A1 (Kimel), 28 July 2016 (28.07.2016), entire document, especially Figs 1-7 8-9

A US 5,497,593 A (Riesberg), 12 March 1996 (12.03.1996), entire document, especially Figs 1-6 1-6, 10-26

A US 2,063,052 A (Robins}, 08 December 1936 (08.12.1936), entire document, especially Figs 1- 1-6, 10-26
7

A US 2018/0141134 A1 (Simpson Strong-Tie Company), 24 May 2018 (24.05.2018), entire 1-6, 10-26
document, especially Figs 1-13

A US 2020/0263413 A1 (500 Group, INC), 20 August 2020 (20.08.2020), entire document, 12-26
especially Figs 1-14B

A EP 2 000 611 A2 (Carlton), 10 December 2008 (10.12.2008), entire document, especially Figs 1 1-26
-19

A US 2008/0066417 A1 (Orchard), 20 March 2008 (20.03.2008), entire document, especially Figs 1-26
1-4

. Further documents are listed in the continuation of Box C.

Special categories of cited documents:

See patent family annex.

"T" later document published after the international filing date o

riority "A" document defining the general state of the art which is not considered date and not in conflict with the ap lication but cited to un
erstand
to be of particular relevance the principle or theory underlying t e invention
"D" document cited by the applicant in the international application "X" document of particular relevance; the claimed invention cannot be
"E" earlier application or patent but published on or atler the international considered novel or cannot be considered to involve an inventive
step
filing date when the document is taken alone
"L" document which mah throw doubts on priority claim(s) or which "Y" document of particular relevance; the claimed invention cannot
is cited to establish t e publication date of another citation or other be considered to involve an inventive step when the document is
special reason (as specihed) combined with one or more other such documents. such
combination
"O" document referring to an oral disclosure, use, exhibition or other means being obvious to a person skilled in the art
"P" document published prior to the international filing date but later than "&" document member of the same patent family
the priority date claimed
Date of the actual completion of the international search Date of mailing of the international search report

14 March 2022• • [APR ,2:"5 2022-l,

- --- , : s- --
0

Name and mailing address of the ISA/US Authorized officer

Mail Stop PCT, Attn: ISA/US, Commissioner for Patents Kari Rodriquez
P.O. Box 1450, Alexandria, Virginia 22313-1450
Facsimile No. 571-273-8300 Telephone No. PCT Helpdesk: 571-272-4300
Fonn PCT/ISA/210 (second sheet) (July 2019)
 INTERNATIONAL SEARCH REPORT International application No.

PCT/US 22/14224

C (Continuation). DOCUMENTS CONSIDERED TO BE RELEVANT

Category• Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim No.

A US 2009/0139153 A1 (Hudson), 04 June 2009 (04.06.2009), entire document • 1-26

Fonn PCT/ISA/210 (continuation of second sheet) (July 2019)