Foldable structure

Abstract

A foldable structure is adjustable between a folded condition for storage and shipping, and an unfolded condition for occupation by one or more users. The foldable structure may be substantially prefabricated at a manufacturing facility, transitioned into its folded condition, and placed into a shipping container for shipping to a destination site. A single foldable structure may be placed in the shipping container, or multiple foldable structures may fit in a standard shipping container. For example, in some embodiments, as many as six foldable structures may fit in a single standard shipping container.

What is claimed is: 
     
         1 . A collapsible structure comprising:
 a plurality of panels arranged in an expanded state of the collapsible structure to form an exterior perimeter of the collapsible structure, each panel comprising:
 a finished exterior surface; 
 a finished interior surface; 
 a first steel track coupling a top portion of the finished exterior surface to a top portion of the finished interior surface; 
 a second steel track coupling a bottom portion of the finished exterior surface to a bottom portion of the finished interior surface; and 
 insulating material between the finished exterior surface and the finished interior surface; and 
   a plurality of anchors, each anchor having one end coupled to the exterior surface of a least one panel and another end of each anchor embedded in a concrete foundation for the collapsible structure.   
     
     
         2 . The collapsible structure of  claim 1 , wherein the finished exterior surface comprises siding to protect the collapsible structure from weather conditions, the siding being comprised of vinyl, wood, steel, aluminum, fiber cement, cement, brick, or plastic. 
     
     
         3 . The collapsible structure of  claim 1 , wherein the finished interior surface comprises painted drywall board or painted magnesium oxide wall board. 
     
     
         4 . The collapsible structure of  claim 1 , wherein at least one of the panels comprises an electrical chase and a plumbing chase. 
     
     
         5 . A collapsible structure comprising:
 at least two finished closed panel walls of the habitable dwelling that can be arranged into an expanded state and a collapsed state, each finished closed panel wall comprising:
 a first panel wall; 
 a second panel wall; 
 a top plate coupled to one end of the first panel wall and the second panel wall; 
 a bottom plate coupled to another end of the first panel wall and the second panel wall; 
   an upper hinge coupled to the top plate of a first finished closed panel wall and to the top plate of a second finished closed panel wall, the upper hinge comprising:
 a first angle bracket including a hinge hole, the first angle bracket being secured along at least one lateral axis to the top plate of the first finished closed panel wall using a plurality of coupling devices; 
 a second angle bracket including a hinge hole, the second angle bracket being secured along at least one lateral axis to the top plate of the second finished closed panel wall using a plurality of coupling devices and a hinge hole; and 
 a hinge pin that pivotably couples the first angle bracket and the second angle bracket that enables the first finished closed panel wall and the second finished closed panel wall to fit flush end-to-end with each other in the expanded state and to be parallel with each other in the collapsed state; and 
   a lower hinge coupled to the bottom plate of the first finished closed panel wall and the bottom plate of the second finished closed panel wall.   
     
     
         6 . The collapsible structure of  claim 5 , wherein the lower hinge further comprises:
 a first angle bracket including a hinge hole, the first angle bracket secured to the first panel wall of the first finished closed panel wall using a plurality of coupling devices;   a second angle bracket including a hinge hole, the second angle bracket secured to the first panel wall of the second finished closed panel wall using a plurality of coupling devices and a hinge hole; and   a hinge pin that pivotably couples the first angle bracket and the second angle bracket via their respective hinge holes which enables the first finished closed panel wall and the second finished closed panel wall to fit flush end-to-end with each other in the expanded state and to be parallel with each other in the collapsed state.   
     
     
         7 . The collapsible structure of  claim 5 , wherein the hinge hole of the first angle bracket is offset from an edge of the first angle bracket and the hinge hole of the second angle bracket is offset from an edge of the second angle bracket. 
     
     
         8 . The collapsible structure of  claim 7 , wherein the hinge pin pivotably couples the first angle bracket and the second angle bracket when the hinge hole of the first angle bracket and the hinge hole of the second angle bracket are vertically aligned to accept the hinge pin. 
     
     
         9 . The collapsible structure of  claim 5 , wherein the finished closed panel wall further comprises insulation material enclosed within the first panel and second panel. 
     
     
         10 . The collapsible structure of  claim 5 , wherein the collapsed state the two finished closed panel walls are apart by not more than 1″. 
     
     
         11 . A structural insulated panel comprising:
 a top plate;   a bottom plate;   a first vertical wall;   a second vertical wall;   insulation material between the first vertical wall and the second vertical wall;   a capillary break secured to the bottom plate, an edge of the first vertical wall, an edge of the second vertical wall;   a detachable angle bracket comprising:
 a vertical axis secured to the first vertical wall; 
 a horizontal axis aligned against the capillary break; 
 a wear resistant pad secured to the horizontal surface of the angle bracket opposite the capillary break. 
   
     
     
         12 . The structural insulated panel of  claim 11 , wherein the first vertical wall comprises siding and the second vertical wall comprises a dry wall board. 
     
     
         13 . The structural insulated panel of  claim 12 , wherein the siding comprises vinyl, wood, steel, aluminum, fiber cement, cement, brick, or plastic. 
     
     
         14 . The structural insulated panel of  claim 12 , wherein the wear resistant pad comprises polytetrafluoroethylene. 
     
     
         15 . A foldable structure comprising:
 a first section comprising:
 a first exterior wall of the foldable structure; and 
 a plurality of interior wall panels being coupled to each other with at least one of the plurality of panels being pivotably coupled to the first exterior wall, 
   a second section comprising:
 a second exterior wall of the foldable structure; 
 two or more wall panels for a third exterior wall of the foldable structure being pivotably coupled to each other and with at least one of the panels for the third exterior wall being pivotably coupled to the second exterior wall; and 
 two or more panels for a fourth exterior wall of the foldable structure being pivotably coupled to each other and with at least one of the panels for the fourth exterior wall being pivotably coupled to the second exterior wall. 
   
     
     
         16 . The foldable structure of  claim 15 , wherein the first section is adjustable between:
 an unfolded condition, in which the plurality of interior wall panels are arranged to define a layout of an interior space for the foldable structure; and   a folded condition, in which the plurality of interior wall panels are pivotably coupled to each other and are collapsed together to substantially eliminate the interior space of the foldable structure.   
     
     
         17 . The foldable structure of  claim 16 , wherein the second section is adjustable between:
 an unfolded condition, in which the third exterior wall panels are aligned end-to-end to form the third exterior wall and the fourth wall panels are aligned end-to-end to form the fourth exterior wall, and an exterior perimeter of the foldable structure is formed by coupling the third exterior wall and the fourth exterior wall to the first exterior wall section; and   a folded condition, in which the one or more panels for the third exterior wall and the one or more panels for the fourth exterior wall are collapsed to substantially minimize a footprint of the second section.   
     
     
         18 . The foldable structure of  claim 16 , wherein the interior wall panels comprise magnesium oxide wall board on a first side and a second side. 
     
     
         19 . A collapsible structure comprising:
 at least two finished closed panel walls that can be arranged into an expanded state and a collapsed state, each finished closed panel wall comprising:
 a first panel wall; 
 a second panel wall; 
 a top plate coupled to one end of each of the first panel wall and the second panel wall; 
 a bottom plate coupled to another end of each of the first panel wall and the second panel wall; and 
 insulation material enclosed between the first panel wall and second panel wall; 
   an upper hinge coupled to the top plate of a first finished closed panel wall and to the top plate of a second finished closed panel wall, the upper hinge comprising:
 a first angle bracket including a hinge hole, the first angle bracket being secured along at least one lateral axis to the top plate of the first finished closed panel wall using a plurality of coupling devices; 
 a second angle bracket including a hinge hole, the second angle bracket being secured along at least one lateral axis to the top plate of the second finished closed panel wall using a plurality of coupling devices and a hinge hole; and 
 a hinge pin that pivotably couples the first angle bracket and the second angle bracket that enables the first finished closed panel wall and the second finished closed panel wall to fit flush end-to-end with each other in the expanded state and to be parallel with each other in the collapsed state; and 
   a lower hinge coupled to the bottom plate of the first finished closed panel wall and the bottom plate of the second finished closed panel wall.   
     
     
         20 . The collapsible structure of  claim 19 , wherein the lower hinge further comprises:
 a first angle bracket including a hinge hole, the first angle bracket secured to the first panel wall of the first finished closed panel wall using a plurality of coupling devices;   a second angle bracket including a hinge hole, the second angle bracket secured to the first panel wall of the second finished closed panel wall using a plurality of coupling devices and a hinge hole; and   a hinge pin that pivotably couples the first angle bracket and the second angle bracket via their respective hinge holes which enables the first finished closed panel wall and the second finished closed panel wall to fit flush end-to-end with each other in the expanded state and to be parallel with each other in the collapsed state.   
     
     
         21 . The collapsible structure of  claim 19 , wherein the hinge hole of the first angle bracket is offset from an edge of the first angle bracket and the hinge hole of the second angle bracket is offset from an edge of the second angle bracket. 
     
     
         22 . The collapsible structure of  claim 21 , wherein the hinge pin pivotably couples the first angle bracket and the second angle bracket when the hinge hole of the first angle bracket and the hinge hole of the second angle bracket are vertically aligned to accept the hinge pin. 
     
     
         23 . The collapsible structure of  claim 19 , wherein in the collapsed state the two finished closed panel walls are apart by at most 1″. 
     
     
         24 . A foldable structure comprising:
 a plurality of exterior walls including a plurality of non-folding exterior walls and a plurality of folding exterior walls;   a plurality of hinges facilitating folding of the folding exterior walls, and pivotably coupling the exterior walls together to define a continuous perimeter of the foldable structure, the foldable structure being adjustable between:
 an unfolded condition, in which the folding exterior walls are unfolded such that the non-folding exterior walls are spaced apart from one another to define an interior space of the foldable structure, the exterior walls being configured to be anchored to a foundation; and 
 a folded condition, in which the folding exterior walls are folded such that the non-folding exterior walls are collapsed together substantially eliminating the interior space of the foldable structure. 
   
     
     
         25 . The foldable structure of  claim 24 , further comprising at least one foldable interior wall, which in the unfolded condition of the foldable structure at least partially defines a room of the interior space of the foldable structure, and which in the folded condition of the foldable structure folds to allow the non-folding exterior walls to be collapsed together substantially eliminating the interior space of the foldable structure. 
     
     
         26 . The foldable structure of  claim 25 , further comprising at least one non-foldable interior wall, which in the unfolded condition of the foldable structure at least partially defines a room of the interior space of the foldable structure, and which in the folded condition of the foldable structure are collapsed together substantially eliminating the interior space of the foldable structure. 
     
     
         27 . The foldable structure of  claim 24 , further comprising plumbing for one or more water sources and/or discharges, the plumbing being disposed in only one interior wall of the foldable structure. 
     
     
         28 . The foldable structure of  claim 24 , the exterior walls further comprising markings designating locations for roof trusses, second story floor trusses, and/or rafters. 
     
     
         29 . The foldable structure of  claim 24 , wherein in the folded condition the foldable structure has a smallest dimension of at most 1 meter. 
     
     
         30 . The foldable structure of  claim 24 , wherein in the folded condition the foldable structure has a smallest dimension which is at most 1/6th that of the same dimension in the unfolded condition.