PORTABLE CORE FACILITY FOR A BUILDING
20190345711 ยท 2019-11-14
Inventors
Cpc classification
E04B1/34336
FIXED CONSTRUCTIONS
E04B2001/3577
FIXED CONSTRUCTIONS
E04B1/34869
FIXED CONSTRUCTIONS
E04B1/35
FIXED CONSTRUCTIONS
E04B2001/2648
FIXED CONSTRUCTIONS
E04B2001/34884
FIXED CONSTRUCTIONS
International classification
E04B1/348
FIXED CONSTRUCTIONS
E04B1/35
FIXED CONSTRUCTIONS
Abstract
A prefabricated building module constructed at a central location and delivered to a construction site via shipping using the intermodal freight transport system and having cold formed wood bracing walls to resist forces in shear and uplift while providing a continuous load path to the foundation system. The module may include interior walls to section the module into rooms and further comprises mechanical, electrical, utility and plumbing aspects of a building, capable of inspection and certification prior to delivery to the construction site. Once arrived at the construction site the building module is anchored to the building foundation and the remainder of the house is built around the building module.
Claims
1. A system and method for fabricating a house using a portable core facility comprising the steps of; combining a plurality of bracing walls into a building module to form a generally rectangular shape, inserting an interior wall into the building module to define a utility room, inserting an interior wall into the building module to define a kitchen, inserting an interior wall into the building module to define a bathroom, attaching framing connectors to the exterior of the outer walls for attaching traditional stick framing to the outer wall for resistance, installing corner castings at the corners of the building module for moving the building module to a construction site, transporting the building module to a building site, constructing a foundation at a building site for receiving the building module and adjacent structures of the house, moving and positioning the building module onto the foundation, anchoring the corner castings to a foundation system, and constructing and attaching the stick framing to create additional rooms of the house.
2. The system of claim 1, further comprising cold forming a plurality of bracing walls by: sawing wood into strips, planing the strips to a thickness that is even, stacking the strips, alternating every other strip end for end to reverse the slope of the grain, spreading a thin layer of adhesive on the face of a first strip, laying a second strip on top of the first strip, spreading adhesive on the second strip and adding a third strip to the adhesive, and inserting an bracing wall into a clamping press to compress and dry.
3. The system of claim 1, further comprising forming one or more shear walls from one or more of the plurality of bracing walls.
4. The system of claim 1, wherein the utility room further comprises inserting components selected from a group consisting of: an electrical system, communication systems, one or more hot water heaters, an HVAC system, a water purification system, a washing machine, a dryer, and a utility tub and sink.
5. The system of claim 1, wherein the kitchen further comprises inserting components selected from a group consisting of: a stove, a refrigerator, a microwave oven, a dishwasher into the kitchen, and a counter and cabinets.
6. The system of claim 1, wherein the bathroom further comprises inserting components selected from a group consisting of: a bidet, a tub, a shower and a sink.
7. The system of claim 1, further comprising attaching a UL Certified Mark and Barcode to the building module for identification.
8. The system of claim 1, further comprising certifying the building module to building codes and standards of the country that the building module will be shipped to.
9-16. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The foregoing and other objects, features, and advantages of the disclosure will be apparent from the following description of embodiments as illustrated in the accompanying figures and drawings.
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DESCRIPTION OF THE ENABLING EMBODIMENT
[0035] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts, goods, or services. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the disclosure and do not delimit the scope of the disclosure.
[0036] All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this disclosure pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
[0037] The present invention will now be described more fully hereinafter with reference to the accompanying figures and drawings, which form a part hereof, and which show, by way of illustration, specific example embodiments. Subject matter may, however, be embodied in a variety of different forms and, therefore, covered or claimed subject matter is intended to be construed as not being limited to any example embodiments set forth herein; example embodiments are provided merely to be illustrative. Likewise, a reasonably broad scope for claimed or covered subject matter is intended. Among other things, for example, subject matter may be embodied as methods, compositions, processes, or systems. The following detailed description is, therefore, not intended to be taken in a limiting sense.
[0038] Throughout the specification and claims, terms may have nuanced meanings suggested or implied in context beyond an explicitly stated meaning. Likewise, the phrase in one embodiment as used herein does not necessarily refer to the same embodiment and the phrase in another embodiment as used herein does not necessarily refer to a different embodiment. It is intended, for example, that claimed subject matter include combinations of example embodiments in whole or in part.
[0039] In general, terminology may be understood at least in part from usage in context. For example, terms, such as and, or, or and/or, as used herein may include a variety of meanings that may depend at least in part upon the context in which such terms are used. Typically, or if used to associate a list, such as A, B or C, is intended to mean A, B, and C, here used in the inclusive sense, as well as A, B or C, here used in the exclusive sense. In addition, the term one or more as used herein, depending at least in part upon context, may be used to describe any feature, structure, or characteristic in a singular sense or may be used to describe combinations of features, structures or characteristics in a plural sense. Similarly, terms, such as a, an, or the, again, may be understood to convey a singular usage or to convey a plural usage, depending at least in part upon context. In addition, the term based on may be understood as not necessarily intended to convey an exclusive set of factors and may, instead, allow for existence of additional factors not necessarily expressly described, again, depending at least in part on context.
[0040] For the purposes of the present invention, a core facility system is presented which is capable of being pre-manufactured according to a specification for a building. The core facility is constructed at a manufacturing site, where skilled trades may construct the core facility in a centralized location, resulting in increased efficiency. The core facility is constructed to take advantage of the intermodal freight transport system, similar to shipping containers, although the present invention does not convert or modify shipping containers. Despite not using actual shipping containers, the present invention takes advantage of corner castings in accordance with standard intermodal shipping containers in order to provide the capability of being transported by the existing intermodal system from a manufacturing facility to a construction site. The resulting core facility as delivered to the construction site may be attached to both a foundation system and roof or floor diaphragm, and/or bracing walls so as to resist forces in shear and uplift and provide a continuous load path to the foundation.
[0041] In one embodiment the present invention utilizes customary construction techniques known in the art for building construction, and may refer to certain construction standards as set forth herein. Unless otherwise further defined herein, terms shall be defined by the International Building Code (IBC) 202 and International Residential Code (IRC) 202, as may be further referenced to other code publications by the International Code Council (ICC), all of which are incorporated by reference in their entirety. Further incorporated herein is the 2015 Wood Frame Construction Manual (WFCM) for One- and Two-Family Dwellings, developed by the American Wood Council's (AWC) Wood Design Standards Committee as may be referenced in the 2015 International Building Code and 2015 International Residential Code. In the event of an inconsistency of such publications and the present invention, the defined terms of the present invention shall prevail.
[0042] For the purposes of the present invention habitable space is defined as a space in a building for living, sleeping, eating or cooking, or used as a home occupation. Bathrooms, toilet rooms, closets, halls, storage or utility spaces and similar areas are not considered habitable spaces.
[0043] The IBC further defines manufactured home, mobile home and modular home all of which are factory manufactured dwelling units (IRC, R202). The system of the present invention may be referred to as a core facility. A core facility will not be a dwelling unit and except for the possible inclusion of kitchen facilities, will not contain any habitable spaces.
[0044] For the purposes of the present invention a mechanical room or a utility room is a room or space in a building or dwelling unit dedicated to the mechanical equipment and its associated electrical equipment, as opposed to rooms intended for human occupancy or storage. Unless a building is served by a centralized heating plant, the size of the mechanical room is usually proportional to the size of the building. The mechanical room may include, but is not limited to, an electrical panel, hot water heater, furnace or boiler, air handler, HVAC equipment, telephone or internet connections and equipment, water service, house traps, utilities such as a washer and dryer, water purification systems, utility tub and sink, and the like.
[0045] For the purposes of the present invention a kitchen is a room or part of a room used for, or designated to be used for, preparation of food. A kitchen is typically equipped with a stove, a sink with hot and cold running water, a refrigerator, counters and kitchen cabinets arranged according to a modular design. Many households have a microwave oven, a dishwasher and other electric appliances. The main function of a kitchen is serving as a location for storing, cooking and preparing food (and doing related tasks such as dishwashing), but it may also be used for dining, entertaining and laundry.
[0046] For the purposes of the present invention an electrical panel refers to a distribution board (also known as panelboard, breaker panel, or electric panel), which is a component of an electricity supply system that divides an electrical power feed into subsidiary circuits, while providing a protective fuse or circuit breaker for each circuit in a common enclosure. Normally, a main switch, and also one or more residual-current devices (RCD) or residual current breakers with overcurrent protection (RCBO), may also be incorporated.
[0047] For the purposes of the present invention a bathroom refers to a room comprising one or more of: a bidet, water closet, lavatory, tub or shower, all of which are located together on the same floor level.
[0048] For the purposes of the present invention corner castings refer to a standardized connector for securing intermodal shipping containers, primarily used for locking an intermodal container in place on a container ship, semi-trailer truck, or railway train, and for lifting of the intermodal shipping container by container cranes and/or sidelifters.
[0049] For the purposes of the present invention intermodal shipping containers refer to a large standardized shipping container, designed and built for intermodal freight transport, meaning these containers can be used across different modes of transportfrom ship to rail to truckwithout unloading and reloading their cargo. These containers are known under a number of names, such as simply container, cargo or freight container, ISO container, shipping, sea or ocean container, container van or (Conex) box, sea or c-can.
[0050] For the purposes of the present invention intermodal freight transport or intermodal system refers to (interchangeably) as the transportation of freight in an intermodal container or vehicle, using multiple modes of transportation (rail, ship, and truck), without any handling of the freight itself when changing modes.
[0051] For the purposes of the present invention a foundation system refers to the lowest load-bearing part of a building, typically below ground level. A foundation may be comprised of a steel, wood, stone or concrete structure that supports a building from underneath.
[0052] For the purposes of the present invention a diaphragm refers to a horizontal or nearly horizontal system acting to transmit lateral forces to the vertical elements. Diaphragm also includes horizontal bracing systems. A roof diaphragm refers to a diaphragm that is located above a room or facility. A floor diaphragm refers to a diaphragm that is located at the base, or below the floor of a room or facility.
[0053] For the purposes of the present invention bracing walls or braced wall panels refer to a full-height section of wall constructed to resist in-plane shear loads through interaction of framing members, sheathing materials, and anchors, such as corner castings. The bracing walls are cold-formed wood which increases the strength and stiffness of the wall. Cold-forming is a composite method of building that uses two or more layers of thin wood, called veneers, oriented in different directions, resulting in a strong monocoque structure. Using different types of wood, the builder can lighten some areas and strengthen other high-stress areas. The cold-formed bracing walls can also have an extra layer of protection either inside or out or both with materials, such as, woven or knitted fiberglass cloth, carbon fiber or kevlar cloth, rigid foam insulation, aluminum honeycomb, or sheet metal, for impact resistance, especially when lightweight, soft timber such as cedar is used. This method lends itself to great flexibility in protection from storms and bad weather. A shear wall is a bracing wall designed and constructed to resist racking from seismic and wind by use of masonry, concrete, steel or wood framing in accordance with Chapter 6 of the IRC and associated with limitations of section R301.2 of the IRC.
[0054] As further referenced in the IBC and IRC, the terms self-contained equipment and shear wall, also in the structural design chapter 16, 1609.1.3, Anchorage against overturning, uplift and sliding, the core facility is a piece of self-contained equipment, neither a modular nor a manufactured home, which incorporates shear walls and frames that become an integral part of a buildings structure and provide resistance against wind-induced overturning, uplift and sliding and provide continuous load paths for these forces to the foundation. For the purposes of the present invention, equipment means piping, ducts, vents, control devices, and other components of systems other than appliances that are permanently installed and integrated to provide control of conditions for buildings.
[0055] Turning to the present invention, a preferred embodiment comprises a core facility comprising bracing walls which contains one or more of a mechanical room, kitchen and bathroom, such facility capable of intermodal transport as is a standardized intermodal shipping container. The present invention further comprises an assembly that contains the primary functional systems of a dwelling or building, including electrical, plumbing, and related mechanical/utility systems. The core facility allows for design, construction, and testing/inspection off-site, prior to shipping to a desired construction site. Upon delivery, the core facility is fastenedor anchoredto the building foundation, and can be further utilized as a storm resistant, shear resistant, load-bearing part of the building's structure. Once the core facility is anchored to the foundation, the habitable spaces of the building may then be constructed around the core facility. While the core facility conforms to the dimensions of a traditional shipping container primarily for ease of shipping via intermodal system, it avoids the need for modification or retrofitting of a shipping container as is typically done for container housing. The core facility of the present invention is capable of being constructed by typical means known in the art, including, but not limited to: concrete block/masonry unit (CMU) construction, stone masonry, glass construction, iron and steel, and wood building, including log and timber framed buildings as may be further described in the Wood Frame Construction Manual, incorporated herein in its entirety.
[0056] The present invention allows for the most complex aspects of a building to be addressed separately from the construction site, resulting in significant time and economic efficiency, particularly in rural areas where skilled tradesmen are scarce or must travel large distances.
[0057] In an exemplary embodiment, the present invention may contain bathrooms and mechanical/utility room for a residence. In another embodiment the present invention contains a kitchen, bathroom and mechanical/utility room, and in another embodiment the present invention contains the public restrooms and utility room for a convenience store. Another embodiment includes two core facilities, one containing restrooms and a utility room and the other a complete commercial kitchen for a commercial restaurant, with all aspects pre-approved by the health department prior to delivery to the construction site.
[0058] The present invention is constructed to utilize the intermodal freight transport system, thus being designed in accordance with intermodal shipping container specifications, although shipping containers themselves are not used with the present invention. The core facility utilizes engineered framing and bracing systems in accordance with intermodal system specifications, including use of corner castings for use during transport and for affixing the core facility to the building foundation, floor diaphragm, and/or roof diaphragm. Typical shipping containers are overbuilt and costly to reconfigure to satisfy the requirements of the present invention, including removal of doors, forklift flooring, and the like, some of which are subjected to chemical treatments. Such approaches are also incompatible with the prevailing trade practices dominant in wood-frame home construction in most developed nations. Bracing systems may include ex-cross bracing internally with the core facility and may be made with or without external walls.
[0059] In another embodiment, the core facility of the present invention is made of standard construction materials. During the construction of the core facility a single location is utilized, allowing for multiple skills to access and service the construction of the core facility. Rather than having the skilled trade workers, such as plumbing, electrical, etc., travel to a construction site for a building, the present invention may be constructed at a central location, where multiple core facilities may be built at a single location, allowing for efficiencies in organizing the various skilled trade worker requirements. Further, certifications and inspections may take place at the manufacturing site rather than the remote construction site, resulting in pre-inspected core facilities which are then capable of delivery to the construction site.
[0060] By utilizing the intermodal freight transport infrastructure, core facilities of the present invention may be made by workers in a single location according to desired specifications, and then shipped to the desired construction site. Standard corner castings allow for fastening to occur in accordance with standard intermodal freight transport, and subsequently anchored to the building foundation and roof assemblies, such as the roof diaphragm and/or bracing walls. In one embodiment, traditional anchoring is utilized, including those common in the construction industry such as anchor bolts or welding as a fitment. Such anchoring may include anchors, ties and straps typically utilized in the construction arts, including but not limited to: screw ties for metal stud construction, Simpson joist anchors, framing straps, wing nut anchors, dovetail anchors, seismic notch (seismic code compliant) anchors, brick ties, channel slot anchors, tie and plate anchors, wire anchors, notch anchors, interlock anchors, and the like. In another embodiment, a twist-lock configuration standard in intermodal system may be utilized as the actual anchor. In another embodiment, a modified twist-lock configuration is utilized where the connector is affixed to a reinforcing bar cage for incorporating into the foundation immediately prior to or prior to curing of the foundation pour. In another embodiment, weld plates are set in the foundation concrete for welding the core facility to the foundation. In another embodiment, anchor bolts which are spatially located down the length of the core facility framing are used to bolt the core facility to the foundation. The resulting core facility further provides a pre-fabricated core facility that is tornado and storm resistant, providing required resistance to uplift and lateral forces.
[0061] Certain embodiments will now be described in greater detail with reference to the figures. Referencing
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[0063] The exemplary embodiment of
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[0071] Those skilled in the art will recognize that the methods and articles of the present invention may be implemented in many manners and as such are not to be limited by the foregoing exemplary embodiments and examples. In other words, functional elements being performed by single or multiple components may be combined into single or multiple embodiments, and alternate embodiments having fewer than, or more than, all of the features described herein are possible.
[0072] Functionality may also be, in whole or in part, distributed among multiple components, in manners now known or to become known. Thus, myriad combinations are possible in achieving the functions, features, interfaces and preferences described herein. Moreover, the scope of the present invention covers conventionally known manners for carrying out the described features and functions and interfaces, as well as those variations and modifications that may be made to the construction components and materials as described herein as would be understood by those skilled in the art now and hereafter.
[0073] Furthermore, the embodiments of methods presented and described in this disclosure are provided by way of example in order to provide a more complete understanding of the present invention. The disclosed methods are not limited to the operations and logical flow presented herein. Alternative embodiments are contemplated in which the order of the various operations is altered and in which sub-operations described as being part of a larger operation are performed independently. While various embodiments have been described for purposes of this disclosure, such embodiments should not be deemed to limit the teaching of this disclosure to those embodiments. Various changes and modifications may be made to the elements and operations described above to obtain a result that remains within the scope of the systems and processes described in this disclosure.
[0074] Alternative embodiments are contemplated in which the order of the various operations is altered and in which sub-operations described as being part of a larger operation are performed independently. While various embodiments have been described for purposes of this disclosure, such embodiments should not be deemed to limit the teaching of this disclosure to those embodiments. Various changes and modifications may be made to the elements and operations described above to obtain a result that remains within the scope of the systems and processes described in this disclosure.