EXPANDABLE BUILDING SYSTEMS
20180142460 ยท 2018-05-24
Inventors
- Brian Gaudio (Pittsburgh, PA, US)
- Drew Brisley (Pittsburgh, PA, US)
- Hallie Dumont (Pittsburgh, PA, US)
Cpc classification
E04B2001/6195
FIXED CONSTRUCTIONS
E04D3/3601
FIXED CONSTRUCTIONS
E04B1/6183
FIXED CONSTRUCTIONS
E04B1/6112
FIXED CONSTRUCTIONS
E04B7/166
FIXED CONSTRUCTIONS
E04B1/02
FIXED CONSTRUCTIONS
International classification
E04B1/343
FIXED CONSTRUCTIONS
Abstract
The present disclosure describes an expandable residential dwelling unit and a set of modular, prefabricated components which can be built offsite, shipped to site, and assembled. The prefabricated components and expandable dwelling unit enable faster, and more cost effective method for adding additional square footage onto a residential dwelling unit. These prefabricated wall components attach to the existing dwelling unit via mechanical connections that maintain a constant thermal and water barrier. Multiple preferred aspects are described herein.
Claims
1. A removable wall assembly for attachment to an exterior wall of a housing unit, wherein the housing unit comprises a first longitudinal wall portion and a second longitudinal wall portion, wherein the first longitudinal wall portion and the second longitudinal wall portion are substantially parallel to one another, wherein the first longitudinal wall portion and the second longitudinal wall portion define an opening therebetween, and wherein the opening defines an opening height and an opening width, and wherein the removable wall assembly is attached the housing unit and defines a wall structure to fill the opening between the first longitudinal wall portion and the second longitudinal wall portion, wherein the removable wall assembly comprises: a patch panel, wherein the patch panel comprises: a first vertical side; a second vertical side, wherein the first vertical side and the second vertical side are substantially parallel to one another; a bottom portion; a top portion, wherein the bottom portion and the top portion are substantial parallel to one another, wherein the first vertical side, the second vertical side, the bottom portion, and the top portion are connected to form the patch panel, and wherein the patch panel has a patch panel height, a patch panel width, and a patch panel thickness; and an attachment mechanism operable between an engaged condition and a disengaged condition; wherein the first vertical side of the patch panel is configured to abut a portion of the first longitudinal wall portion when the patch panel is attached to the housing unit, wherein the bottom potion of the patch panel is configured to abut a portion of a floor system of the housing unit when the patch panel is attached to the housing unit, and wherein the attachment mechanism is configured to releasably attach the patch panel to the housing unit when the attachment mechanism is in the engaged condition.
2. The removable wall assembly of claim 1, wherein the attachment mechanism is configured to releasably attach the bottom portion of the patch panel to the floor system of the housing unit.
3. The removable wall assembly of claim 1, wherein the attachment mechanism is configured to releasably attach the first vertical side of the patch panel to the first longitudinal wall portion of the housing unit.
4. The removable wall assembly of claim 1, wherein the attachment mechanism comprises a cam latch configured to cammingly engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
5. The removable wall assembly of claim 1, wherein the attachment mechanism comprises a key latch, wherein the key latch is operable between an open condition and a locked condition, wherein the key latch is configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit when the key latch is moved from the open condition to the locked condition.
6. The removable wall assembly of claim 1, wherein the attachment mechanism comprises an attachment pin configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
7. The removable wall assembly of claim 1, wherein the attachment mechanism comprises an attachment fin configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
8. The removable wall assembly of claim 1, wherein the attachment mechanism comprises an attachment bracket configured releasably attach the patch panel to the housing unit.
9. The removable wall assembly of claim 1, wherein the patch panel defines a first patch panel and wherein the removable wall assembly further comprising a second patch panel, wherein the second patch panel comprises: a first vertical side; a second vertical side, wherein the first vertical side and the second vertical side of the second patch panel are substantially parallel to one another; a bottom portion; a top portion, wherein the bottom portion and the top portion of the second patch panel are substantial parallel to one another, wherein the first vertical side, the second vertical side, the bottom portion, and the top portion of the second patch panel are connected to form the second patch panel, and wherein the second patch panel has a second patch panel height, a second patch panel width, and a second patch panel thickness; and a second attachment mechanism operable between an engaged condition and a disengaged condition; wherein the first vertical side of the second patch panel is configured to abut the second vertical portion of the first patch panel when the first and second patch panels are attached to the housing unit, wherein the second vertical side of the second patch panel is configured to abut a portion of the first longitudinal wall portion when the second patch panel is attached to the housing unit wherein the bottom potion of the second patch panel is configured to abut a portion of a floor system of the housing unit when the second patch panel is attached to the housing unit, and wherein the second attachment mechanism is configured to releasable attach the patch panel to the housing unit when the second attachment mechanism is in the engaged condition.
10. The removable wall assembly of claim 9, wherein the top portion of the first patch panel and the top portion of the second patch panel define a removable wall assembly width, and wherein the removable wall assembly width is substantially the same as the opening width.
11. A method for horizontally expanding a housing unit, comprising the removable wall assembly of claim 1, wherein the method comprises: releasing the patch panel from the housing unit by moving the attachment mechanism from the engaged condition to the disengaged condition; removing the patch panel from the housing unit; installing a horizontal addition onto the housing unit; releasably attaching the addition to the housing unit; and reattaching the patch panel to the horizontal addition by moving the attachment mechanism from the disengaged condition to the engaged condition.
12. The method of claim 11, wherein the attachment mechanism comprises a cam latch configured to cammingly engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
13. The method of claim 11, wherein the attachment mechanism comprises a key latch, wherein the key latch is configured to be moved between an open condition and a locked condition, wherein the key latch is configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit when the key latch is moved from the open condition to the locked condition.
14. The method of claim 11, wherein the attachment mechanism comprises an attachment pin configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
15. The method of claim 11, wherein the attachment mechanism comprises an attachment fin configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
16. The method of claim 11, wherein the attachment mechanism comprises an attachment bracket configured releasably attach the patch panel to the housing unit.
17. A patch panel, wherein the patch panel comprises: a first vertical side; a second vertical side, wherein the first vertical side and the second vertical side are substantially parallel to one another; a bottom portion; a top portion, wherein the bottom portion and the top portion are substantial parallel to one another, wherein the first vertical side, the second vertical side, the bottom portion, and the top portion are connected to form the patch panel, and wherein the patch panel has a patch panel height, a patch panel width, and a patch panel thickness; and an attachment mechanism operable between an engaged condition and a disengaged condition; wherein the first vertical side of the patch panel is configured to abut a portion of a wall portion of a modular housing unit when the patch panel is attached to the modular housing unit, wherein the bottom potion of the patch panel is configured to abut a portion of a floor system of the modular housing unit when the patch panel is attached to the housing unit, and wherein the attachment mechanism is configured to releasable attach the patch panel to the modular housing unit when the attachment mechanism is in the engaged condition.
18. The patch panel of claim 17, wherein the attachment mechanism comprises a cam latch configured to cammingly engage a corresponding attachment portion of a modular housing unit and releasably attach the patch panel to the modular housing unit.
19. The patch panel of claim 17, wherein the attachment mechanism comprises a key latch, wherein the key latch is configured to be moved between an open condition and a locked condition, wherein the key latch is configured to engage a corresponding attachment portion of a modular housing unit and releasably attach the patch panel to the modular housing unit when the key latch is moved from the open condition to the locked condition.
20. The patch panel of claim 17, wherein the attachment mechanism comprises an attachment pin configured to engage a corresponding attachment portion of a modular housing unit and releasably attach the patch panel to the modular housing unit.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various features and characteristics of an expandable building system, and more specifically a removable wall system, described in this specification may be more thoroughly understood by reference to the accompanying figures, in which:
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[0061] The reader will appreciate the foregoing features and characteristics, as well as others, upon considering the following detailed description of the expandable building system according to this specification.
DETAILED DESCRIPTION
[0062] This specification is generally directed to expandable building systems, and more specifically, removable wall systems for use with modular building structures. However, they are not limited to such extemporary environments.
[0063] Generally speaking, numerous aspects described throughout the specification can be used in the construction of modular structures, prefabricated structures, as well as site-built structures. The removable wall assembly can allow modular structures to grow and expand as well as contrast as the needs of the building owners/occupants change. In one aspect, the removable wall assembly may permit the expansion of a modular residential structure its current footprint to a larger horizontal footprint, for example a rear or side addition that permits additional square footage to be added to the residential structure. In addition, the removable wall assembly may permit a modular residential structure to be contracted and an addition removed, for example when a family is looking to downsize after the children have left the home.
[0064] In other aspects, the removable wall assembly may allow for the replacement of exterior walls on structures designed as permanent buildings. In one aspect, the removable wall assembly may allow a building owner to easily replace the wall structures of a building to update the structural aspects as well as the visual aspect of a building structure. For example, the removable wall assembly may allow for ease of replacing a building with a vinyl siding with one of a wooded siding, a siding of a different color, or another type of exterior appearance, such as brick, or stucco. The ease of removal and replacement with the removable wall assembly can reduce labor costs and replacement wall assemblies can be constructed offsite and shipped to the location of the building which can reduce the time and labor costs associated with replacing a roof structure. Additionally, the removable wall assembly also may facilitate the easy removal and replacement of walls as technology improves and more efficient building materials are produced, such as increased thermal resistivity materials to allow a structure to be more energy efficient or technological upgrades, such as smart panels having built-in electronic features.
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EXAMPLES
Example 1
[0091] A removable wall assembly for attachment to an exterior wall of a housing unit. The housing unit comprises a first longitudinal wall portion and a second longitudinal wall portion. The first longitudinal wall portion and the second longitudinal wall portion are substantially parallel to one another. The first longitudinal wall portion and the second longitudinal wall portion define an opening therebetween. The opening defines an opening height and an opening width. The removable wall assembly is attached the housing unit and defines a wall structure to fill the opening between the first longitudinal wall portion and the second longitudinal wall portion. The removable wall assembly comprises a patch panel. The patch panel comprises a first vertical side and a second vertical side, wherein the first vertical side and the second vertical side are substantially parallel to one another. The patch panel further comprises a bottom portion and a top portion, wherein the bottom portion and the top portion are substantial parallel to one another. The first vertical side, the second vertical side, the bottom portion, and the top portion are connected to form the patch panel. The patch panel has a patch panel height, a patch panel width, and a patch panel thickness. The patch panel further comprises an attachment mechanism operable between an engaged condition and a disengaged condition. The first vertical side of the patch panel is configured to abut a portion of the first longitudinal wall portion when the patch panel is attached to the housing unit. The bottom potion of the patch panel is configured to abut a portion of a floor system of the housing unit when the patch panel is attached to the housing unit. The attachment mechanism is configured to releasably attach the patch panel to the housing unit when the attachment mechanism is in the engaged condition.
Example 2
[0092] The removable wall assembly of Example 1, wherein the attachment mechanism is configured to releasably attach the bottom portion of the patch panel to the floor system of the housing unit.
Example 3
[0093] The removable wall assembly of Example 1, wherein the attachment mechanism is configured to releasably attach the first vertical side of the patch panel to the first longitudinal wall portion of the housing unit.
Example 4
[0094] The removable wall assembly of Examples 1, 2, or 3, wherein the attachment mechanism comprises a cam latch configured to cammingly engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
Example 5
[0095] The removable wall assembly of Examples 1, 2, or 3, wherein the attachment mechanism comprises a key latch, wherein the key latch is operable between an open condition and a locked condition, wherein the key latch is configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit when the key latch is moved from the open condition to the locked condition.
Example 6
[0096] The removable wall assembly of Examples 1, 2, or 3, wherein the attachment mechanism comprises an attachment pin configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
Example 7
[0097] The removable wall assembly of Examples 1, 2, or 3, wherein the attachment mechanism comprises an attachment fin configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
Example 8
[0098] The removable wall assembly of Examples 1, 2, or 3, wherein the attachment mechanism comprises an attachment bracket configured releasably attach the patch panel to the housing unit.
Example 9
[0099] The removable wall assembly of Examples 1, 2, 3, 4, 5, 6, 7, or 8, wherein the patch panel defines a first patch panel and wherein the removable wall assembly further comprising a second patch panel. The second patch panel comprises a first vertical side and a second vertical side, wherein the first vertical side and the second vertical side of the second patch panel are substantially parallel to one another. The second patch panel further comprises a bottom portion and a top portion, wherein the bottom portion and the top portion of the second patch panel are substantial parallel to one another. The first vertical side, the second vertical side, the bottom portion, and the top portion of the second patch panel are connected to form the second patch panel. The second patch panel has a second patch panel height, a second patch panel width, and a second patch panel thickness. The second patch panel comprises a second attachment mechanism operable between an engaged condition and a disengaged condition. The first vertical side of the second patch panel is configured to abut the second vertical portion of the first patch panel when the first and second patch panels are attached to the housing unit. The second vertical side of the second patch panel is configured to abut a portion of the first longitudinal wall portion when the second patch panel is attached to the housing unit. The bottom potion of the second patch panel is configured to abut a portion of a floor system of the housing unit when the second patch panel is attached to the housing unit. The second attachment mechanism is configured to releasable attach the patch panel to the housing unit when the second attachment mechanism is in the engaged condition.
Example 10
[0100] The removable wall assembly of Example 9, wherein the top portion of the first patch panel and the top portion of the second patch panel define a removable wall assembly width, and wherein the removable wall assembly width is substantially the same as the opening width.
Example 11
[0101] A method for horizontally expanding a housing unit, comprising the removable wall assembly of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10. The method comprises releasing the patch panel from the housing unit by moving the attachment mechanism from the engaged condition to the disengaged condition. The method further comprises removing the patch panel from the housing unit, installing a horizontal addition onto the housing unit, releasably attaching the addition to the housing unit, and reattaching the patch panel to the horizontal addition by moving the attachment mechanism from the disengaged condition to the engaged condition.
Example 12
[0102] The method of Example 11, wherein the attachment mechanism comprises a cam latch configured to cammingly engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
Example 13
[0103] The method of Example 11, wherein the attachment mechanism comprises a key latch, wherein the key latch is configured to be moved between an open condition and a locked condition, wherein the key latch is configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit when the key latch is moved from the open condition to the locked condition.
Example 14
[0104] The method of Example 11, wherein the attachment mechanism comprises an attachment pin configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
Example 15
[0105] The method of Example 11, wherein the attachment mechanism comprises an attachment fin configured to engage a corresponding attachment portion of the housing unit and releasably attach the patch panel to the housing unit.
Example 16
[0106] The method of Example 11, wherein the attachment mechanism comprises an attachment bracket configured releasably attach the patch panel to the housing unit.
Example 17
[0107] A patch panel, wherein the patch panel comprises a first vertical side and a second vertical side, wherein the first vertical side and the second vertical side are substantially parallel to one another. The patch panel further comprises a bottom portion and a top portion, wherein the bottom portion and the top portion are substantial parallel to one another. The first vertical side, the second vertical side, the bottom portion, and the top portion are connected to form the patch panel. The patch panel has a patch panel height, a patch panel width, and a patch panel thickness. The patch panel further comprises an attachment mechanism operable between an engaged condition and a disengaged condition. The first vertical side of the patch panel is configured to abut a portion of a wall portion of a modular housing unit when the patch panel is attached to the modular housing unit. The bottom potion of the patch panel is configured to abut a portion of a floor system of the modular housing unit when the patch panel is attached to the housing unit. The attachment mechanism is configured to releasable attach the patch panel to the modular housing unit when the attachment mechanism is in the engaged condition.
Example 18
[0108] The patch panel of Example 17, wherein the attachment mechanism comprises a cam latch configured to cammingly engage a corresponding attachment portion of a modular housing unit and releasably attach the patch panel to the modular housing unit.
Example 19
[0109] The patch panel of Example 17, wherein the attachment mechanism comprises a key latch, wherein the key latch is configured to be moved between an open condition and a locked condition, wherein the key latch is configured to engage a corresponding attachment portion of a modular housing unit and releasably attach the patch panel to the modular housing unit when the key latch is moved from the open condition to the locked condition.
Example 20
[0110] The patch panel of Example 17, wherein the attachment mechanism comprises an attachment pin configured to engage a corresponding attachment portion of a modular housing unit and releasably attach the patch panel to the modular housing unit.
[0111] Various features and characteristics of removable roof system are described in this specification and illustrated in the drawings to provide an overall understanding of the disclosed apparatus. It is understood that the various features and characteristics described in this specification and illustrated in the drawings can be combined in any suitable manner regardless of whether such features and characteristics are expressly described or illustrated in combination in this specification. The Inventors and the Applicant expressly intend such combinations of features and characteristics to be included within the scope of this specification. As such, the claims can be amended to recite, in any combination, any features and characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Furthermore, the Applicant reserves the right to amend the claims to affirmatively disclaim features and characteristics that may be present in the prior art, even if those features and characteristics are not expressly described in this specification. Therefore, any such amendments will not add new matter to the specification or claims, and will comply with written description, sufficiency of description, and added matter requirements (e.g., 35 U.S.C. 112(a) and Article 123(2) EPC). The systems and methods described in this specification can comprise, consist of, or consist essentially of the various features and characteristics described in this specification.
[0112] The examples presented herein are intended to illustrate potential and specific implementations of the present disclosure. It can be appreciated that the examples are intended primarily for purposes of illustration of the disclosure for those skilled in the art. No particular aspect of the examples are necessarily intended to limit the scope of the present disclosure. For example, those skilled in the art will appreciate that the fasteners described herein (e.g., screws) may be replaced or supplemented by other suitable fastening means including a variety of other types of mechanical fastening devices (e.g., nails, rivets, magnets, or others). In another example, a particular choice of construction material (e.g., aluminum, plastic, steel, etc.) may be replaced or supplemented by another type of material which is suitable for the same or similar structure or function.
[0113] Any element expressed herein as a means for performing a specified function is intended to encompass any way of performing that function including, for example, a combination of elements that performs that function. Furthermore the disclosure, as may be defined by such means-plus-function claims, resides in the fact that the functionalities provided by the various recited means are combined and brought together in a manner as defined by the appended claims. Therefore, any means that can provide such functionalities may be considered equivalents to the means shown herein.
[0114] It will be appreciated that, for convenience and clarity of disclosure, terms describing relative orientation or spatial positioning such as proximal, distal, vertical, horizontal, up, down, top, front, back, bottom, upward, or downward may be used at times herein with respect to the drawings and text description in association with various aspects of the disclosure. However, such terms are primarily used for illustrative purposes and are not necessarily intended to be limiting in nature.
[0115] It is to be understood that the figures and descriptions of the present disclosure have been simplified to illustrate elements that are relevant for a clear understanding of the present disclosure, while eliminating, for purposes of clarity, other elements. Those of ordinary skill in the art will recognize, however, that these and other elements may be desirable. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements is not provided herein. It should be appreciated that the figures are presented for illustrative purposes and not as construction drawings. Omitted details and modifications or alternative aspects are within the purview of persons of ordinary skill in the art. For example, there may be variations to these diagrams or the operations described herein without departing from the spirit of the disclosure.
[0116] It can be appreciated that, in certain aspects of the present disclosure, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, to provide an element or structure or to perform a given function or functions. Except where such substitution would not be operative to practice certain aspects of the present disclosure, such substitution is considered within the scope of the present disclosure.
[0117] While various aspects of the disclosure have been described herein, it should be apparent, however, that various modifications, alterations and adaptations to those aspects may occur to persons skilled in the art with the attainment of some or all of the advantages of the present disclosure. The disclosed aspects are therefore intended to include all such modifications, alterations and adaptations without departing from the scope and spirit of the present disclosure as claimed.
[0118] Any patent, publication, or other disclosure material identified in this specification is incorporated by reference into this specification in its entirety unless otherwise indicated, but only to the extent that the incorporated material does not conflict with existing descriptions, definitions, statements, or other disclosure material expressly set forth in this specification. As such, and to the extent necessary, the express disclosure as set forth in this specification supersedes any conflicting material incorporated by reference. Any material, or portion thereof, that is incorporated by reference into this specification, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. Applicant reserves the right to amend this specification to expressly recite any subject matter, or portion thereof, incorporated by reference.
[0119] The grammatical articles one, a, an, and the, as used in this specification, are intended to include at least one or one or more, unless otherwise indicated. Thus, the articles are used in this specification to refer to one or more than one (i.e., to at least one) of the grammatical objects of the article. By way of example, a component means one or more components, and thus, possibly, more than one component is contemplated and can be employed or used in an implementation of the described processes, compositions, and products. Further, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.