Subassembly for enclosure component manufacture

Abstract

An enclosure component having first surface layer, a core layer and a second surface layer. The core layer has three rectangular foam panels, each with a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges. The second and third foam panels are identical, and each has an internal passage between the first and second edges that is offset from the mid-point of the panel, and an elongate recess on a surface of the panel spanning the distance between the first and second edges. The fourth edge of the first panel is arranged side-by-side with the third edge of the second panel, and the third edge of the first panel is arranged side-by-side with the third edge of the third panel. An elongate reinforcement spline is in each recess. The first surface layer is bonded to the core layer, and the second surface layer is bonded to the core layer.

What is claimed is: 
     
         1 . An enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising:
 a first surface layer having a first face and an opposed second face;   a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;   the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;   the second and third foam panels each having (a) an internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges;   the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;   an elongate reinforcement spline in each recess;   a second surface layer having a first face and an opposed second face; and   the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer.   
     
     
         2 . The enclosure component of  claim 1 , wherein the core layer further comprises:
 a planar rectangular fourth foam panel and a planar rectangular fifth foam panel, each of the fourth and fifth foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fourth and fifth foam panels being oriented along the length of the enclosure component;   the fourth edge of the fourth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the fourth edge of the fifth foam panel arranged in a side-by-side relationship with the third edge of the second foam panel; and   the first and second edges of each of the fourth and fifth foam panels each has a same third linear dimension that is different from the first linear dimension.   
     
     
         3 . The enclosure component of  claim 2 , wherein the third linear dimension is less than the first linear dimension. 
     
     
         4 . The enclosure component of  claim 2 , wherein the first edges of the first, second, third fourth and fifth foam panels are in aggregate equal to the length of the enclosure component. 
     
     
         5 . The enclosure component of  claim 1 , wherein the third edge and the fourth edge of each of the first, second and third foam panels each equals the width of the enclosure component. 
     
     
         6 . The enclosure component of  claim 1 , wherein the second and third foam panels are each symmetrical about a dividing line extending between the third and fourth edges and are each asymmetrical about a dividing line extending between the first and second edges. 
     
     
         7 . The enclosure component of  claim 1 , wherein the internal passage of each of the second and third foam panels extends parallel to the recess and the internal passage and recess are offset from the fourth edge by an identical distance such that the internal passage and the recess are aligned within the thickness. 
     
     
         8 . The enclosure component of  claim 7 , wherein the second and third foam panels include a further internal passage that is parallel to the recess and offset from the fourth edge a different distance than the recess. 
     
     
         9 . The enclosure component of  claim 1 , wherein the internal passage in the first foam panel extends between the first and second edges midway between the third and fourth edges. 
     
     
         10 . The enclosure component of  claim 1 , wherein one of the second or third foam panels is rotated one hundred eighty degrees relative to the other about an axis extending in a direction of the thickness that is perpendicular to the length and width. 
     
     
         11 . The enclosure of component of  claim 1 , wherein each recess is formed on the second face of the core layer. 
     
     
         12 . An enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising:
 a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component;   a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;   the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;   the first and second edges of each of the first, second, third and fourth surface panels A each has a same third linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension;   the second and third foam panels each having (a) a linear first internal passage between the first and second edges that is offset in a same offset direction from a mid-point of the panel a first select distance, and (b) an elongate recess on a surface of the foam panel spanning the distance between the first and second edges;   the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;   the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A;   an elongate reinforcement spline in each recess;   a surface layer B having a first face and an opposed second face; and   the second face of the surface layer A being bonded to the first face of the core layer, and the first face of the surface layer B being bonded to the second face of the core layer.   
     
     
         13 . The enclosure component of  claim 12 , wherein the surface layer A further comprises:
 a planar rectangular fifth surface panel A and a planar rectangular sixth surface panel A, each of the fifth and sixth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the fifth and sixth surface panels A being oriented along the length of the enclosure component; and   the first and second edges of each of the fifth and sixth surface panels A each has a same fourth linear dimension that is different from the third linear dimension.   
     
     
         14 . The enclosure component of  claim 13 , wherein the fourth linear dimension is less than the third linear dimension. 
     
     
         15 . The enclosure component of  claim 13 , wherein the first edges of the first, second, third, fourth, fifth and sixth surface panels A are in aggregate equal to the length of the enclosure component. 
     
     
         16 . The enclosure component of  claim 12 , wherein the third edge of the first, second, third, fourth, fifth and sixth surface panels A each equals the width of the enclosure component. 
     
     
         17 . The enclosure component of  claim 12 , further comprising an elongate planar rectangular first joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the first joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge. 
     
     
         18 . The enclosure component of  claim 17 , wherein the first joinder spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first joinder spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the first joinder spline being oriented along the length of the enclosure component, with each of the first and second edges of the first joinder spline having a linear dimension less than 50 percent of the third linear dimension. 
     
     
         19 . The enclosure component of  claim 18 , wherein the first joinder spline is bonded to the first face of the core layer. 
     
     
         20 . The enclosure component of  claim 18 , wherein the first and second edges of the first joinder spline have a linear dimension less than 25 percent of the third linear dimension. 
     
     
         21 . The enclosure component of  claim 18 , wherein the first and second edges of the first joinder spline have a linear dimension less than 10 percent of the third linear dimension. 
     
     
         22 . The enclosure component of  claim 12 , wherein the reinforcement spline has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the reinforcement spline having an aspect ratio, defined by the linear dimension of the third edge thereof divided by the first edge thereof, of 20 or more, and the first and second edges of the reinforcement spline being oriented along the length of the enclosure component, with each of the first and second edges of the reinforcement spline having a linear dimension less than fifty percent of the third linear dimension. 
     
     
         23 . The enclosure component of  claim 22 , wherein the reinforcement spline is bonded to the core layer. 
     
     
         24 . The enclosure component of  claim 22 , wherein the first and second edges of the reinforcement spline having a linear dimension less than 25 percent of the fourth linear dimension. 
     
     
         25 . The enclosure component of  claim 22 , wherein the first and second edges of the reinforcement spline having a linear dimension less than 10 percent of the fourth linear dimension. 
     
     
         26 . The enclosure component of  claim 12 , wherein the first joinder spline is steel. 
     
     
         27 . The enclosure component of  claim 12 , wherein one or more of the surface panels A is cement board. 
     
     
         28 . The enclosure component of  claim 12 , wherein the reinforcement spline is wooden. 
     
     
         29 . The enclosure component of  claim 12 , wherein the surface layer B comprises:
 a planar rectangular first surface panel B and a planar rectangular second surface panel B, each of which has a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, with the first and second edges being oriented along the length of the enclosure component; and   the fourth edge of the first surface panel B arranged in a side-by-side relationship with the third edge of the second surface panel B.   
     
     
         30 . The enclosure component of  claim 12 , further comprising an elongate planar rectangular second joinder spline overlapping the fourth edge of the first surface panel B and the third edge of the second surface panel B, the second joinder spline bonded to the first surface panel B proximate to its fourth edge and bonded to the second surface panel B proximate to its third edge. 
     
     
         31 . The enclosure component of  claim 30 , wherein the second joinder spline is steel. 
     
     
         32 . The enclosure component of  claim 12 , wherein the core layer includes a linear second internal passage parallel to the first internal passage, and a linear third internal passage parallel to the first internal passage, the first, second and third internal passages forming an internal passage array, the internal passages of which are spaced apart from each other by an integer multiple of a grid distance. 
     
     
         33 . The enclosure component of  claim 32 , wherein the first surface layer includes a plurality of apertures proximate to an edge of the first surface layer that is along the length of the enclosure component, and the plurality of apertures are spaced apart from each other by one-half of an integer multiple of the grid distance. 
     
     
         34 . The enclosure component of  claim 33 , wherein at least two of the plurality of apertures are bounded by at least two of the internal passages of the internal passage array, and each aperture of the at least two of the plurality of apertures is spaced apart from each passage of the at least two internal passages by an integer multiple of an offset distance. 
     
     
         35 . The enclosure component of  claim 34 , wherein the offset distance is one-quarter the grid distance. 
     
     
         36 . A foldable enclosure component for a building structure, the enclosure component having a length, a width and a thickness and comprising:
 first and second enclosure component sub-portions, each such enclosure component sub-portion including:   a surface layer A having a first face, an opposed second face and comprising a planar rectangular first surface panel A, a planar rectangular second surface panel A, a planar rectangular third surface panel A and a planar rectangular fourth surface panel A, each of the first, second, third and fourth surface panels A having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second, third and fourth surface panels A being oriented along the length of the enclosure component;   a core layer having a first face, an opposed second face and comprising a planar rectangular first foam panel, a planar rectangular second foam panel, and a planar rectangular third foam panel, each of the first, second and third foam panels having a first edge, an opposed second edge, a third edge separating the first and second edges and an opposed fourth edge separating the first and second edges, the first and second edges of the first, second and third foam panels being oriented along the length of the enclosure component;   the first and second edges of each of the second and third foam panels each has a same first linear dimension, and the third and fourth edges of each of the second and third foam panels each has a same second linear dimension;   the first and second edges of each of the first, second, third and fourth surface panels A each has a same fourth linear dimension, and the third and fourth edges of each of the first, second, third and fourth surface panels A has the second linear dimension;   the second and third foam panels each having an elongate recess on a surface of the panel spanning the distance between the first and second edges;   the fourth edge of the first foam panel arranged in a side-by-side relationship with the third edge of the second foam panel, and the third edge of the first foam panel arranged in a side-by-side relationship with the third edge of the third foam panel;   the fourth edge of the first surface panel A arranged in a side-by-side relationship with the third edge of the second surface panel A, the fourth edge of the second surface panel A arranged in a side-by-side relationship with the third edge of the third surface panel A, and the fourth edge of the third surface panel A arranged in a side-by-side relationship with the third edge of the fourth surface panel A;   an elongate reinforcement spline in each recess;   an elongate planar rectangular joinder spline overlapping the fourth edge of the first surface panel A and the third edge of the second surface panel A, the joinder spline bonded to the first surface panel A proximate to its fourth edge and bonded to the second surface panel A proximate to its third edge;   a second surface layer having a first face and an opposed second face; and   the second face of the first surface layer being bonded to the first face of the core layer, and the first face of the second surface layer being bonded to the second face of the core layer;   a beam assembly comprising a first beam joined to a second beam by a first hinge assembly defining a first hinge line;   the first enclosure component sub-portion joined to the first beam and joined to the second beam;   the second enclosure component sub-portion joined to the first beam and joined to the second beam; and   the first enclosure component sub-portion divided along the first hinge line and the second enclosure sub-portion divided along the first hinge line to define a first enclosure component portion joined to the first beam and a second enclosure component portion joined to the second beam.   
     
     
         37 . The foldable enclosure component of  claim 36 , wherein the beam assembly further comprises a third beam joined to the second beam by a second hinge assembly defining a second hinge line;
 the first enclosure component sub-portion is further joined to the third beam;   the second enclosure component sub-portion is further joined to the third beam; and   the first enclosure component sub-portion is further divided along the second hinge line and the second enclosure sub-portion is further divided along the second hinge line to define a third enclosure component portion joined to the third beam.   
     
     
         38 . A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising:
 fabricating a first workpiece by performing at least the following steps:   forming a first surface layer by arranging a plurality of planar rectangular first surface panels side-by-side to form one or more first seams between a respective one or more of the plurality of first surface panels;   placing an elongate planar first joinder spline over one of the one or more first seams to form a first sub-assembly;   forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel;   forming a second surface layer by arranging a plurality of planar rectangular second surface panels side-by-side to form one or more second seams between a respective one or more of the plurality of second surface panels;   placing a second elongate planar joinder spline over one of the one or more second seams to form a second sub-assembly;   joining the first sub-assembly to the first face of the core layer; and   joining the second sub-assembly to the second face of the core layer;   thereby to fabricate the first workpiece.   
     
     
         39 . A method of manufacturing an enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising:
 fabricating a first workpiece by performing at least the following steps:   placing at least two elongate planar rectangular first joinder splines spaced-apart a first select distance to form a first spline sub-assembly;   forming a core layer with a first face and an opposed second face by (a) providing a planar rectangular first foam panel having a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges; (b) providing a planar rectangular second foam panel and a planar rectangular third foam panel of the same length and width as the second foam panel, each having (i) a first edge, an opposed second edge, a third edge separating the first and second edges, an opposed fourth edge separating the first and second edges and a mid-point, and (ii) an internal passage between the first and second edges that is offset in a same offset direction from the mid-point of the foam panel a first select distance; (c) placing the third edge of the second foam panel in a side-by-side relationship with the fourth edge of the first foam panel; and (d) placing the third edge of the third foam panel in a side-by-side relationship with the third edge of the first foam panel;   joining the first spline sub-assembly to the first face of the core layer;   placing at least two elongate planar rectangular second joinder splines spaced-apart a second select distance to form a second spline sub-assembly;   joining the second spline sub-assembly to the second face of the core layer;   forming a first surface layer by arranging three planar rectangular first surface panels side-by-side to provide a first middle panel flanked by a first pair of seams, where the first middle panel is dimensioned so that the first pair of seams is separated by the first select distance;   joining the first surface layer to the first face of the core layer and the first spline sub-assembly positioned so that the first pair of seams overlie the first joinder splines;   forming a second surface layer by arranging three planar rectangular second surface panels side-by-side to provide a second middle panel flanked by a second pair of seams, where the second middle panel is dimensioned so that the second pair of seams is separated by the second select distance; and   joining the second surface layer to the second face of the core layer and the second spline sub-assembly positioned so that the second pair of seams overlie the second joinder splines;   thereby to fabricate the first workpiece.   
     
     
         40 . The method of  claim 38 , further comprising cutting an access point through the first surface layer to communicate with the internal passage. 
     
     
         41 . The method of  claim 38 , further comprising cutting a door aperture or a window aperture through the workpiece. 
     
     
         42 . The method of  claim 38 , further comprising cutting the first workpiece parallel to the third edge of the first foam panel into two enclosure component portions. 
     
     
         43 . The method of  claim 38 , further comprising:
 fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece;   providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line;   cutting the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular second enclosure component sub-portion;   cutting the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular third enclosure component sub-portion with a side having a linear dimension equal to the first beam length, and a planar rectangular fourth enclosure component sub-portion;   joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and   joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.   
     
     
         44 . The method of  claim 38 , further comprising:
 fabricating a second workpiece in accordance with the steps recited for fabricating the first workpiece;   providing a beam assembly comprising a first beam having a first beam length joined to a second beam having a second beam length by a first hinge assembly defining a first hinge line, with a third beam having a third beam length joined to the second beam by a second hinge assembly defining a second hinge line;   cutting in a first cutting step the first workpiece parallel to the third edge of the first foam panel of the first workpiece at a distance from an edge of the first workpiece equal to the first beam length, to form a planar rectangular first enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a first cut line from a planar rectangular second enclosure component sub-portion;   cutting in a second cutting step the second enclosure component sub-portion parallel to the first cut line, and at a distance from a first cut line edge of the second enclosure component sub-portion equal to the second beam length, to form from the second enclosure component sub-portion a planar rectangular first enclosure component third sub-portion with a side having a linear dimension equal to the second beam length, separated along a second cut line from a planar rectangular fourth enclosure component sub-portion;   cutting in a third cutting step the second workpiece parallel to the third edge of the first foam panel of the second workpiece at a distance from an edge of the second workpiece equal to the first beam length, to form a planar rectangular fifth enclosure component sub-portion with a side having a linear dimension equal to the first beam length, separated along a third cut line from a planar rectangular sixth enclosure component sub-portion;   cutting in a fourth cutting step the sixth enclosure component sub-portion parallel to the third cut line, and at a distance from a third cut line edge of the sixth enclosure component sub-portion equal to the second beam length, to form from the sixth enclosure component sub-portion a planar rectangular enclosure component seventh sub-portion with a side having a linear dimension equal to the second beam length, separated along a fourth cut line from a planar rectangular eighth enclosure component sub-portion;   joining the first enclosure component sub-portion and the third enclosure component sub-portion to the first beam; and   joining the second enclosure component sub-portion and the fourth enclosure component sub-portion to the second beam.   
     
     
         45 . A foldable enclosure component for a building structure, the enclosure component comprising:
 a floor component formed by:
 two of the enclosure components as recited in  claim 1 ; and 
 a first beam assembly positioned between and joined to the enclosure components of the floor component, the first beam assembly including a first beam and a second beam attached to the first beam by a first hinge to define a first hinge line along which the enclosure components are cut to define a first portion of the floor component and a second portion of the floor component pivotally joined to each other by the first hinge to allow the floor component to move between a folded position and an unfolded position; and 
   a ceiling component formed by:
 two of the enclosure components as recited in  claim 1 ; 
 a second beam assembly positioned between and joined to the enclosure components of the ceiling component, the second beam assembly including a first beam, a second beam attached to the first beam by a first hinge to define a first hinge line, and a third beam attached to the second beam by a second hinge to define a second hinge line, the enclosure components of the ceiling component are cut to along the first and second hinge lines of the second beam assembly to define a first portion of the ceiling component, a second portion of the ceiling component pivotally joined to the first portion of the ceiling component by the first hinge, and a third portion of the ceiling component pivotally joined to the second portion of the ceiling component by the second hinge to allow the ceiling component to move between a folded position and an unfolded position. 
   
     
     
         46 . A foldable enclosure component for a building structure, the enclosure component comprising:
 a floor component formed by:
 two of the enclosure components as recited in  claim 12 ; and 
 a first beam assembly positioned between and joined to the enclosure components of the floor component, the first beam assembly including a first beam and a second beam attached to the first beam by a first hinge to define a first hinge line along which the enclosure components are cut to define a first portion of the floor component and a second portion of the floor component pivotally joined to each other by the first hinge to allow the floor component to move between a folded position and an unfolded position; and 
   a ceiling component formed by:
 two of the enclosure components as recited in  claim 12 ; 
 a second beam assembly positioned between and joined to the enclosure components of the ceiling component, the second beam assembly including a first beam, a second beam attached to the first beam by a first hinge to define a first hinge line, and a third beam attached to the second beam by a second hinge to define a second hinge line, the enclosure components of the ceiling component are cut to along the first and second hinge lines of the second beam assembly to define a first portion of the ceiling component, a second portion of the ceiling component pivotally joined to the first portion of the ceiling component by the first hinge, and a third portion of the ceiling component pivotally joined to the second portion of the ceiling component by the second hinge to allow the ceiling component to move between a folded position and an unfolded position.