Granted Patent B2

US 12,209,403 · App. 17/971,230 · Granted Jan 28, 2025

Inventors: Paolo Tiramani (Las Vegas, NV); Galiano Tiramani (Las Vegas, NV); Kyle Denman (North Las Vegas, NV)

Assignee: Boxabl Inc.

E04B1/344B32B5/024B32B5/18B32B5/20B32B5/245B32B5/32B32B15/046E04B1/343E04B1/34384E04B1/3442E04B1/34853E04C2/284B32B2262/101B32B2419/00E04B1/34317

Abstract

Claims (40)

1. An enclosure member for a building structure, comprising:

a planar laminate having a generally linear edge comprising a first facing layer; a layer of foam having a first face and a second opposing face; and a second facing layer; the first facing layer fastened to the first face of the layer of foam, and the second facing layer fastened to the second opposing face of the layer of foam;

a first flange surface positioned on the planar laminate;

a first inclined fastener shelf element joined to the first flange surface to form a first V-shaped recess extending inwardly into the planar laminate; and

the first inclined fastener shelf element oriented to direct a leading portion of a screw or nail fastener away from the planar laminate, through the generally linear edge and into an abutting planar enclosure component;

wherein at least one of:

(i) the enclosure member further comprises a second flange surface, and a second inclined fastener shelf element joined to the second flange surface to form a second V-shaped recess extending inwardly into the planar laminate; or

(ii) the enclosure member further comprises a first aperture aligned with the first V-shaped recess and a vertically oriented portion of the first flange surface, the first aperture provides access to the V-shaped recess; or

(iii) the first facing layer is selected from the group consisting of (a) a structural layer comprising a plurality of structural panels of inorganic oxide, (b) a layer of metallic sheet, and (c) a combination of a protective layer comprising a plurality of structural panels of inorganic oxide and a layer of metallic sheet.

2. The enclosure member as in claim 1 , wherein if (ii), the first aperture is formed in the first facing layer.

3. The enclosure member as in claim 1 , wherein the first flange surface is disposed between the first facing layer and the first face of the layer of foam.

4. The enclosure member as in claim 1 , further comprising:

a web surface joined to the first inclined fastener shelf element, the web surface and the first flange surface spaced apart by the inclined fastener shelf element along an axis that is perpendicular to the web surface.

5. The enclosure member as in claim 1 , wherein the first inclined fastener shelf element is adapted to support fasteners at an angle of less than ninety degrees relative to the generally linear edge of the planar laminate.

6. An enclosure member for a building structure, comprising:

a planar laminate having a generally linear edge comprising a first facing layer; a layer of foam having a first face and a second opposing face; and a second facing layer; the first facing layer fastened to the first face of the layer of foam, and the second facing layer fastened to the second opposing face of the layer of foam;

a C-shaped abutting end cap secured to the planar laminate and configured to be secured to an abutting planar enclosure component, the abutting end cap comprising:

an elongate web surface abutting the generally linear edge of the planar laminate;

a first inclined fastener shelf extending from a first edge of the elongate web surface oriented to direct a leading portion of a screw or nail fastener through the web surface and away from the planar laminate into the abutting planar enclosure component;

a second inclined fastener shelf extending from a second edge of the elongate web surface and oriented to direct a leading portion of a screw or nail fastener through the web surface and away from the planar laminate into the abutting planar enclosure component; and

a first elongate flange surface and a second elongate flange surface, the first elongate flange surface and the second elongate flange surface being spaced-apart by a distance, regions of the first and second elongate flanges are canted inward towards each other proximate the first and second inclined fastener shelve such that the first elongate flange surface is canted inward to join the first inclined fastener shelf at a first point to provide access to the first inclined fastener shelf for receipt of the screw or nail fastener by the first inclined fastener shelf and the second elongate flange surface is canted inward to join the second inclined fastener shelf at a second point to provide access to the first inclined fastener shelf for receipt of the screw or nail fastener by the first inclined fastener.

7. The enclosure member as in claim 6 , wherein the distance spacing apart the first and second elongate flange surfaces adapted to receive between them at least the generally linear edge of the layer of foam.

8. The enclosure member as in claim 6 , further comprising an elongate cavity wall joined to each of the first and second elongate flange surfaces, the elongate cavity wall being spaced from and generally parallel to the elongate web surface, and spanning the distance spacing apart the first and second elongate flange surfaces, to define a reinforcement channel.

9. The enclosure member as in claim 6 , further comprising apertures cut at spaced apart locations in the first facing layer proximate to the first inclined fastener shelf to provide access to the first inclined fastener shelf through the first facing layer.

10. The enclosure member as in claim 9 , further comprising plugs to plug the apertures.

11. The enclosure member as in claim 6 , wherein the first facing layer and the second facing layer are each selected from the group consisting of (a) a structural layer comprising a plurality of structural panels of magnesium oxide, (b) a layer of metallic sheet, and (c) a combination of (i) a protective layer comprising a plurality of structural panels of inorganic oxide and (ii) a layer of metallic sheet.

12. The enclosure member as in claim 6 , wherein the abutting end cap further comprises:

a receiving slot formed in and opening outwardly from an exterior surface of the elongate web surface away from the C-channel shape, the receiving slot adapted to receive a sealing head.

13. The enclosure member as in claim 6 , wherein the first inclined fastener shelf is adapted to support fasteners at an angle of less than ninety degrees relative to the elongate web surface.

14. The enclosure member as in claim 6 , wherein the regions of the first and second elongate flanges are canted inward at an angle of approximately thirty degrees.

15. The enclosure member as in claim 6 , wherein the first inclined fastener shelf has an incline of approximately sixty degrees relative to a portion of the first elongate flange surface that is perpendicular to the elongate web surface.

16. A reinforced enclosure member for a building structure, comprising:

(a) a planar laminate having a generally linear edge comprising a first facing layer; a layer of foam having a first face and a second opposing face; and a second facing layer; the first facing layer fastened to the first face of the layer of foam, and the second facing layer fastened to the second opposing face of the layer of foam;

(b) a reinforced end cap comprising:

(1) a first elongate flange surface joined to an elongate web surface at a first junction, a second elongate flange surface joined to the elongate web surface at a second junction, the first elongate flange surface and the second elongate flange surface being spaced-apart by a distance, the web surface, the first elongate flange surface and the second elongate flange surface generally forming a C-channel shape;

(2) an elongate cavity wall joined to each of the first and second elongate flange surfaces, the elongate cavity wall being spaced from and generally parallel to the elongate web surface, and spanning the distance spacing apart the first and second elongate flange surfaces, to define a reinforcement channel between the elongate cavity wall and the elongate web surface; and

(3) a filler reinforcement within the reinforcement channel; and

(c) the reinforced end cap secured to the generally linear edge of the planar laminate, with the distance spacing apart the first and second elongate flange surfaces adapted to receive between them at least the generally linear edge of the layer of foam.

17. The reinforced enclosure member as in claim 16 , wherein the first facing layer and the second facing layer are each selected from the group consisting of (a) a structural layer comprising a plurality of structural panels of inorganic oxide, (b) a layer of metallic sheet, and (c) a combination of a protective layer comprising a plurality of structural panels of inorganic oxide and a layer of metallic sheet.

18. The reinforced enclosure member as in claim 16 , wherein the filler reinforcement comprises a dried slurry of magnesium oxide board pieces and epoxy adhesive.

Assignments (3)

Continuity (4)

References Cited (400)