Prefabricated building with self-aligning sections and method of manufacture and assembly of same

Abstract

A method for manufacture and assembly of a structure includes manufacturing, at a first location, wall sections and floor/ceiling sections. The sections include structural portions and optionally external and interior finish features. The sections have self-aligning features, which may include rotatable attachments. At least some of the sections are attached to one another with rotatable attachments to define a structure segment. The structure segment may be placed in an assembled position, with the rotatable attachments fixed, and additional finish features are removably applied. The additional finish features are removed, and the structure segment is removed from the assembled position to a compact orientation for shipping. The structure segment may be placed in a shipping container for transport. The structure segment is transported in the folded position to a second location. The structure segment is moved to a final assembly position at the second location. The structure segment is placed on a foundation, removed from its compact orientation to an assembled orientation, and fixed in place. Finish features may be added. Additional structure segments may be placed on the foundation to complete a structure.

1 . A method of manufacture and assembly of a structure, comprising the steps of: 
 providing a plurality of structure sections having structural supports, said sections having predefined mechanical connections with one another;    placing the structure sections in a compact shipping orientation at a first location;    transporting the structure sections to a second location,    removing said structure sections from said shipping orientation to an assembled position in accordance with said predefined mechanical connections, and fixing the relative orientations of said sections, at a second location; and    completing internal and external finish features, whereby the structure is completed.    
   
   
       2 . The method of  claim 1 , further comprising the steps of providing a second structure section, positioning said second structure section adjacent to said structure section at said second location, unfolding said second structure section, and joining said structure sections to form a building.  
   
   
       3 . The method of  claim 1 , wherein at least two of said structure sections are rotatably connected.  
   
   
       4 . The method of  claim 1 , wherein, prior to said step of placing, internal and external finish features have been applied on at least one of said structure sections.  
   
   
       5 . The method of  claim 1 , wherein said structure sections have utility components therein.  
   
   
       6 . The method of  claim 1 , wherein said utility components comprise cables.  
   
   
       7 . The method of  claim 1 , wherein said utility components comprise pipes.  
   
   
       8 . A prefabricated structure, comprising: 
 a plurality of structure sections, each of said structure sections comprising structural supports, said sections being adapted for self-alignment to one another.    
   
   
       9 . The structure of  claim 8 , wherein at least two of said sections are rotatably attached to one another.  
   
   
       10 . The structure of  claim 9 , wherein a first one of said sections is a first floor/ceiling section, and a second one of said sections is a first wall section rotatably attached to said first floor/ceiling section, said structure further comprising a second wall section rotatably attached to said first floor/ceiling section, and a second floor/ceiling section rotatably and slidably attached to said first and second wall sections.  
   
   
       11 . The structure of  claim 10 , wherein said first and second wall sections have an open and a closed orientation relative to said second floor/ceiling section.  
   
   
       12 . The structure of  claim 10 , further comprising a plurality of first arms rotatably attached at one end thereof to said first wall section, said first arms each having an wheel on an opposite end thereof, said wheels riding on tracks defined in said second floor/ceiling section.  
   
   
       13 . The structure of  claim 12 , wherein each of said first arms is attached to one of said structural supports of said first wall section.  
   
   
       14 . The structure of  claim 12 , further comprising a plurality of second arms rotatably attached at one end to said second wall section, said second arms each having a wheel on an opposite end thereof, said wheels riding on said tracks defined in said second floor/ceiling section.  
   
   
       15 . The structure of  claim 9 , wherein a first one of said sections is a first floor/ceiling section, and a second one of said sections is a second floor/ceiling section, said structure further comprising a first wall section comprising a first upper wall portion and a first lower wall portion, and a second wall section comprising a second upper wall portion and a second lower wall portion, said first lower wall portion being rotatably attached to said first floor/ceiling section and to said first upper wall portion; said first upper wall portion being rotatably attached to said second floor/ceiling section; said second lower wall portion being rotatably attached to said first floor/ceiling section and to said second upper wall portion; said second upper wall portion being rotatably attached to said second floor/ceiling section.  
   
   
       16 . A segment of a prefabricated structure, comprising a first floor/ceiling section, first and second wall sections attached to said first floor/ceiling section, a second floor/ceiling section attached to said first and second wall sections, third and fourth wall sections attached to said second floor/ceiling section, and a third floor/ceiling section, attached to said third and fourth wall sections, said segment being configurable in a shipping position to fit within a standard shipping container.  
   
   
       17 . The segment of  claim 16 , wherein said segment is configurable in an assembled position to define first and second stories of a structure for human occupancy.  
   
   
       18 . The segment of  claim 16 , wherein each of said section is rotatably attached to at least one of said sections.  
   
   
       19 . A section of a building, comprising structural supports, a first finish surface, and self-aligning means for attaching to a second building section.  
   
   
       20 . The building section of  claim 19 , wherein said self-aligning attachment means comprises means for rotatably attaching to a second building section.  
   
   
       21 . The building section of  claim 19 , further comprising a second finish surface, utility lines intermediate said first and second finish surfaces, and flexible connectors to said utility lines.