Note: Descriptions are shown in the official language in which they were submitted.
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MODULAR PRE-FABRICATED HOUSE
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to prefabricated houses and, more specifically, to a
modular,
expandable prefabricated house.
Background Information
At least three issues are important to the prefabricated housing industry:
transportation, ease of assembly, and customer choice. Presently, the market
is currently
broken down into several basic types of prefabricated houses. One of the
largest types of
prefabricated housing is modular housing. Modular housing is, typically, a two
story
house constructed in a factory and shipped onsite. Such houses are, typically,
designed
and constructed in a variety of layouts or models. These layouts, however, are
only
minimally adaptable by the customer. That is, while certain features, for
example a closet,
may be added or subtracted from a room, the general shape and layout of the
house cannot
be changed or adapted to the customer's preference. Such houses require
substantial finish
work on site involving all the trades, a foundation and significant
construction time.
Additionally, during transportation, modular housing requires wide load
permits, state-to-
state handoffs and special permits and costs.
Another form of prefabricated houses are manufactured housing, more commonly
known as a double wide. A double wide generally includes components of a lower
quality
than modular houses and are almost always single story. A double wide,
however,
requires less interior finish but still requires a certain amount of
finishing. The layout of a
double wide is generally restricted to the prebuilt design and cannot be
adapted by the
customer. During transport, a double wide requires a wide load permit, state-
to-state
handoffs, and special permits and costs.
Similar to a double wide is trailer homes. Trailer homes are complete houses
which require very little, if any finishing. The layout of a trailer house is
generally
restricted to the prebuilt design and cannot be adapted by the customer.
Trailer homes are
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sized to be about 60 feet x 9 feet x 7 feet and may be transported without
wide load
permits. Trailer homes are, generally, inexpensive due to their physical
dimension.
Yet another form of prefabricated housing is panelized construction. Panelized
construction is where house panels are finished in a factory and transported
to a building
S site. This method of construction is often viewed as a false economy because
the finishing
of the house, as opposed to the framing, is typically the most expensive part
of
construction. Although panelizing creates semi finished walls, it leaves the
floor space,
appliances and closets to be finished on site mitigating many of the savings.
There are also temporary offices, or site trailers, which are similar in
dimension to
a trailer house. Temporary offices are typically rendered in steel, and are
simply a secure
weatherproof location for storage, office and meeting areas as well as a
communication
receiver for telephone/fax and/or a computer network.
There are also temporary shelters made from a variety of very low cost
products
which can be static or folding in a variety of novel ways. Temporary shelters
are best
differentiated from houses by their lack of smart space, i.e., closets
kitchens, bathroom or
anything that requires floor space, as this does not lend itself to being
packed flat. Such
shelters are, almost without exception, single story.
There is, therefore, a need for a modular prefabricated house which may be
adapted
to a customer selected layout.
There is a further need for a modular prefabricated house which may be
collapsed
into one or more modules which may be transported without legal restrictions.
There is a further need for a modular prefabricated house that includes a
plurality
of multi-frame openings that may be adapted to a customer selected layout and
which
enable the modules to be coupled in more than one layout.
SUMMARY OF THE INVENTION
These needs, and others, are met by the disclosed invention which provides a
prefabricated house having two or more modules, each module having one or more
foldable walls. The foldable walls have one or more multi-frame openings that
may be
converted to doors, windows or other openings. Thus, the individual modules
are
structured to be joined at the multi-frame openings in more than one
configuration. For
example, if each module was rectangular and included a multi-frame opening at
the middle
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point of each wall, the modules could be joined along adjacent longitudinal
walls thereby
forming, generally, a square shaped layout, or, the modules could be joined
with a
longitudinal wall coupled to a lateral wall, thereby forming, generally, a T-
shaped layout.
The multi-frame openings are disposed at set distances regardless of the shape
of
the module. Thus, modules of different shapes may be joined as the multi-frame
openings
will be spaced properly. Additionally, there may be more than one opening
between
modules. For example, two rectangular modules, each having a plurality of
multi-frame
openings along the longitudinal wall, may be joined by doors at each end of
the joined
longitudinal wall.
The multi-frame openings are created as part of the frame during the
construction
of the module. The multi-frame openings may then be covered, for example, by
dry wall.
During construction of the house, the covering is removed at each multi-frame
opening
where modules need to be joined. Alternatively, if the layout of the house is
known, the
multi-frame openings may be converted to the proper type of aperture, that is
doors,
windows, and such, during construction of the module. However, if during
construction
of the house the customer desires a new window or door, a multi-frame opening
may also
be converted to an aperture at the construction site. Because each type of
module is
manufactured in an identical manner, regardless of where the apertures will be
disposed,
manufacturing costs are reduced. However, because each type of module includes
a
plurality of multi-frame openings, each module is still adaptable to the
layout chosen by
the customer.
The invention is suitable for providing houses at the top end of the portable
housing market, that is, comparable to modular housing, without the inherent
drawbacks of
modular housing. That is, each module is substantially finished and each
module, when
the foldable walls are folded, has dimensions of less than about 66 feet, by
10 feet, by 12
feet. Thus, wide load, excessive shipping costs and problems which can add
substantially
to the cost of the house are avoided. That is, the time to transport the prior
art 16 foot wide
product is substantial given the speed restrictions, toll access problems and
because the
prior art product created such general highway congestion that the product was
often
forced to be transported at night by many states.
An additional mechanical novelty of the preferred embodiment described herein
are the spatial and mechanical fastening relationships between the modules and
accessories
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that create an entire building system rather than a single product.
Furthermore, each final
product is produced by the system without compromise to function. Indeed,
without
exception, the final product is substantially improved over its traditionally
built
counterpart on the same cost basis.
The prior art described hereinbefore can build at best one finished style of
house or
temporary structure, whereas the preferred embodiment can create, the
following each in
an array of customer choosable floor plans, layouts and sizes.
- 900 square foot cottages to 4800 square foot luxury homesteads,
- multi-level condo,
- single and multi story motels,
- entire retail towns in many sizes,
- temporary offices, and
- temporary shelter and drop shipped 3rd-world housing.
Rather than a single product, as in the prior art, the preferred embodiment
describes
a series of "smart" connectable modules and accessories, inter-connectable in
a multiple of
configurations and details to create a multiple of end uses in a multiple of
sizes and levels
of finish. The formulas, spatial relationships and strict adherence to first
principles in
order for the system to work without compromise to acceptable cost, style,
traditional and
floor plan flexibility are aspects of the mechanical combinations in multiple
areas as
described herein.
Much of the manufactured housing, construction and shelter industry, has
chosen to
ignore the limitations of shipping oversize highway loads or has simply not
had the
resources to overcome the obstacles. It should be noted that the entirety of
the preferred
embodiment is shippable within standard international 60 foot high-cube (ISO)
shipping
containers.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following
description
of the preferred embodiments when read in conjunction with the accompanying
drawings
in which:
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Figure 1 is an isometric view of a modular house according to the present
invention
having modules shown in both the installed and uninstalled configurations.
Figure lA is an isometric view of a modular house according to the present
invention having two modules.
Figure 1 B is a front view of a multi-frame opening.
Figure 2 is an isometric view of various multi-unit buildings formed from
prefabricated modules.
Figure 3 is an isometric view of a module in the first, closed position.
Figure 4 is an isometric view of a module in between the first, closed
position and
the second, open position.
Figure 5 is an isometric view of a module in between the first, closed
position and
the second, open position.
Figure 6 is an isometric view of a module in between the first, closed
position and
the second, open position.
Figure 7 is an isometric view of a module in the second, open position.
Figure 8 is a top view of a module in the second, open position.
Figures 9A-9K show the stages of construction of a prefabricated house system
assembled from a series of modules. Figure 9A is an isometric view of the
prefabricated
house in a shipping configuration on a truck. Figures 9B-9F are isometric
views of the
transition of a core module from the first, closed position to the second,
open position as
also shown in Figures 3-7. Figure 9G is an isometric view of the core module
with roof
supports installed. Figures 91-9J show the expansion of the roof module.
Figure 9K shows
the completed prefabricated home.
Figure 10 is a floor plan view of an alternate core module.
Figure 11 is a floor plan view of an alternate core module.
Figure 12A is a side view of a module with a roof in the second, open
position.
Figure 12B is a side view of a module with a roof in the first, closed
position.
Figure 13 is a partial floor plan view of a prefabricated house having a spare
room
attached in one location.
Figure 14 is a partial floor plan view of a prefabricated house having a spare
room
attached in another location.
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Figure 15 is a partial floor plan view of a prefabricated house having a spare
room
attached in another location.
Figure 16 is a floor plan view of two modules coupled along their longitudinal
walls.
Figure 17 is a floor plan view of two modules joined together with a
longitudinal
wall coupled to a lateral wall.
Figure 18 is a schematic side view of a floor panel and a wall panel.
Figure 19 is a schematic side view of a floor panel and a wall panel with a
pipe to
assist in preventing a crease in a covering when the panels are in the first,
folded position.
Figure 20 is a schematic side view of a floor panel and a wall panel with a
hinge.
Figure 21 is a schematic side view of a floor panel and a wall panel with
insulation
therebetween.
Figure 22 is a schematic side view of a roof panel and a wall panel.
Figure 23 is a schematic view of a covering for a roof panel.
Figure 24 is a schematic side view of the interior of a floor panel and a wall
panel
showing the flexible conduit used to protect cabling and vents.
Figure 25 is a schematic side view of a baseboard with multiple outlets.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in Figure 1, a prefabricated house system 1 is assembled from a
series of
modules 10. The prefabricated house system 1 may have as few as two modules 10
or
include a plurality of joined modules 10. As such, the prefabricated house
system I may
be used to construct a prefabricated house 3. The prefabricated house 3 may be
any size,
such as the smaller prefabricated house 3A shown in Figure lA, or a larger
prefabricated
house 3, as shown in Figure 1. Alternatively, as shown in Figure 2, the same
modules 10
may be used to construct a multi-level condo 2, single and multi story motels
(not shown),
retail buildings, temporary offices, or temporary shelter. The preferred
embodiment is
component driven, i.e., each module 10 is one of several modules 10 to
complete the
prefabricated house 3 not a finished product in and to itself. Moreover, as
described
below, the modules are factory built and shippable within standard
international container
(ISO) dimensions, nationwide and worldwide.
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The prefabricated house system I includes mathematically interrelated modules
10
and accessories that are configurable to create hundreds of affordable floor
plans and
layouts to meet a user's needs. As described below, the prefabricated house
system 1
includes modules 10 having ports 5 located at set locations with hidden multi-
frame
openings 20. The multi-frame openings 20 allow users to upgrade their house
using hand
tools to add complete second stories, or simple additions such as dormers or a
fireplace.
As shown in Figures 1-6, a prefabricated house 3 includes two or more modules
10,
each module 10 having one or more foldable panels 18. The foldable panels 18
have one
or more multi-frame openings 20, described below. The two or more modules 10
are
structured to be joined at the one or more multi-frame openings 20. At least
one of the two
or more modules 10 is a core module 11 having a fixed space portion 12 and a
passive
space portion 14, discussed below (Figs. 4-5). The fixed space portion 12 has
non-foldable
walls 16; the passive space portion 14 includes the foldable panels 18. The
foldable panels
18 are movable from a first, closed position to second open position. When the
foldable
panels 18 of a module 10 are in the first, folded position, as shown in Figure
3, the module
10 has dimensions of less than about 66 feet, by 10 feet, by 12 feet, which,
as shown in
Figure 6, is sized to be shipped by a truck 7. Each of the modules 10 includes
substantially
finished trim.
Core modules 11 (Figs. 1-6) are sized to standard international container
sizes
(ISO). The value of this is standardized worldwide shipping, the preferred
embodiments
come in two basic core sizes, one with an outside height dimension of 10 foot
for (ISO)
standard and a second size of 11 foot for national shipping. The difference in
the two sizes
is the height of the internal ceiling in the completed prefabricated house 3.
That is, the
former ISO sized module yields an eight-foot ceiling, the national sized
module, a nine-
foot ceiling. The outside dimension of all core modules 11 therefore fall
within the
following parameters height from about 9 feet to 12 feet, width from about 5
feet to 10 feet
length from 20 feet to 66 feet.
The core modules 11 are a series of connectable modules 10 which are,
generally,
indoor rooms such as, but not limited to, bedrooms, bathrooms, recreation
rooms, study,
living rooms, dining rooms, play rooms, libraries, kitchens, laundry rooms,
single garages,
double garages, triple garages, great rooms, artist's studios, offices, and
storage rooms.
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This is compared to the broader category of modules 10 that may further
include, but is not
limited to, decks, porches, and other outdoor structures.
As noted above, each core module 11 includes a fixed space portion 12 and a
passive space portion 14. Fixed space does not compress. That is, fixed space
is rigid and
S does not include foldable panels 18. Fixed space is typically any space that
has
functionality beyond providing volume. For example, the following would
qualify as
fixed space: closets, bathrooms, kitchens, storages, laundry rooms or house
mechanical
space, as well as corridors and stairs. Conversely, passive space is
compressible space,
i.e., that which may be folded. Typically, the passive space is not laden with
fixtures, etc.
The foldable panels 18 of the core module 11 may be folded into the passive
space portion
14 when the core module 11 is in the shipping configuration. Fixed and passive
space is
achieved by a mechanical opening of foldable panels 18. As used herein,
"foldable panels
18" are typically walls, but may also include other foldable components such
as, but not
limited to, foldable decks, ceilings, dividers, or roofs.
Each core module 11 includes a plurality of connection points, each of which
is a
multi-frame opening 20. The multi-frame openings 20 are built into the module
frame 22
during construction, but may be disposed under a covering 19 over the frame
22, such as
dry wall. The multi-frame openings 20 on separate core modules 11 are disposed
in
predetermined locations so that multiple core modules 11 may be joined
together when the
modules are aligned in various predetermined configurations. Thus, when core
modules
11 are joined together, any pair of multi-frame openings 20 may have the
covering 19
removed so that a passageway is formed. Other multi-frame openings 20 may be
converted into windows or other such openings. Construction of the multi-frame
opening
20 may be traditional or steel framed or a combination or hybrid, including
wood, steel,
plastics, adhesives, screws, nails, chalkboard, vinyl's glass, rubber and/or
not limited to
other synthetics.
A multi-frame opening 20 is shown in Figure 1 B. The multi-frame opening 20
may be disposed between any two spaced apart studs 21, 21 A within the frame
22, and
incorporates the studs 21, 21A into the multi-frame opening 20. The multi-
frame opening
20 also includes a plurality of cross members 23, 24, 25, 26, 27, 28, 29. Two
of the cross
members, at the top and bottom 23, 29, may be integral with the module frame
22. The
top and bottom cross-members 23, 29 along with the medial cross-members 24,
25, 26, 27,
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28 are removably coupled to the studs 21, 21A and maybe removed as required to
construct the appropriate sized openings. For example, if the opening is to be
a door, the
medial and bottom cross-members 24, 25, 26, 27, 28, 29 could be removed. If
the opening
is to be a window, the upper cross-members 24, 25, and 26 may be removed. If
the
opening is to be a fireplace, the lower cross-members 26, 27, 28 may be
removed. Any
cross-member 23, 24, 25, 26, 27, 28, 29 that is left in place is coupled to
the studs 21, 21A
in a manner known in the prior art sufficient to support any additional
component, for
example, but not limited to, a window frame or fireplace insert. The actual
number of
cross-members may vary between and within a prefabricated house system 1. That
is, as
shown, there are seven cross-members 23, 24, 25, 26, 27, 28, 29. There may,
however, be
additional or fewer cross-members.
In the preferred embodiment the prefabricated house 3 includes two core
modules
11 which are subsequently divided into room functionalities. Additionally,
whereas the
prior art prefabricated homes typically had a roof panel that included a
finished pitch roof
with the roof panel opening in excess of about 90 degrees, as shown in Figure
7, the
preferred embodiment includes an interior flat roof 30. The interior flat roof
30 may
include a first roof panel 31 and a second roof panel 32 (shown in ghost on
Figure 3, and
removed for clarity on Figures 4-6). The first roof panel 31 may be integrated
into the
fixed space portion 12. The second roof panel 32 is a separate structure that
is joined to
the core module 11. The second roof pane132 opens only to about 90 degrees,
within a 5
degrees reasonable tolerance either side relative to the hinged walls 38
(described below).
Figures 3-7 show the method in which the passive space portion 14 of a core
module 11 unfolds. Note, all foldable panels 18 open to 90 degrees plus or
minus a
manufacturing tolerance of 5 degrees. The foldable panels 18 may be rigid or
have
multiple sub-panels pivotally connected in an accordian-like manner. As shown
in Figure
3, the core module 11 is in a first, closed position. That is, the foldable
panels 18 are each
in the first, closed position. The fixed space portion 12 includes, in
addition to the first roof
panel 31, a plurality of fixed walls 34 (Fig. 4), a stair case 35, and a floor
36. The passive
space portion 14 includes a plurality of foldable panels 18 that include, but
are not limited
to, hinged walls 38, a floor panel 40, and multi-function walls 42 (detailed
below). The
foldable panels 18, while in the first, folded position have, essentially,
collapsed the
passive space.
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As shown in Figure 4, the passive space portion floor panel 40 has been
rotated
about 90 degrees to be generally horizontal and substantially planar with the
fixed portion
floor panel 36. In Figure 5, a longitudinal wall panel 44 has been rotated to
be generally
vertical and substantially parallel to the fixed portion walls 34. In Figure
6, the foldable
panels 18 that are the passive portion hinged walls 38 have been moved into
the second,
open position. In Figure 7, the passive portion second roof panel 32 has been
moved into
the final position which is substantially co-planar with the fixed portion
first roof panel 31.
Thus, the compressed, passive space portion 14 has been expanded into a
useable space.
The foldable panels 18 may be coupled to the frame 22 or other components of
the fixed
space portion 12 by hinges 133 (Figure 20). The hinges 133 maybe mechanical
hinges or
flexible hinges, surface mounted or recessed, and including, but not limited
to, metal,
plastic, leather, ferrous or non ferrous material. The second roof panel 32
may be hinged
or be disjointed and slid into position.
The longitudinal wall panel 44 may unfold with one of the hinges described
above.
In a preferred embodiment, the longitudinal wall panel 44 also displaces
itself
approximately a wall width, about 5 inches to 10 inches. The displacement can
be
achieved with a hinge structured to produce a linear slide and radial
rotation, or a radial
rotation and linear slide. Alternatively, a cammed hinge, a hinge that rotates
open in a
non-radial orbit, or a leash hinge which has no prescribed arc but limits
total movement,
may be used.
Notwithstanding the above, any of the foldable panels 18 may open with any
form
of hinge as described above in any combination of materials as cited above.
Additionally,
the above foldable panels 18 may not be hinged and may be erected loosely as
in any other
construction using but not limited to welding, screwing, bolting, nailing, use
of adhesives,
or any combination thereof in any combination of materials.
In the preferred embodiment, the longitudinal wall panel 44 is no longer than
the
passive portion floor panel 40 by a margin more than about twice a typical
wall width.
The passive portion hinged walls 38 should not exceed, in any dimension, the
shortest
floor dimension of passive portion floor panel 40 by more than a factor of 28
percent.
Each foldable panel 18 may be sheathed in protective film during production.
The
protective film remains in place until the module 10 is at the job site, and
may be removed
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anytime thereafter. In the preferred embodiment the protective film remains in
place until
afler the completion of erection, site work and all trade egress.
As shown in Figure 8, when the core module 11 is expanded, the fixed space
portion 12 includes a staircase 35, a bathroom area 50, a laundry area 52, and
a kitchen
area 54. These areas are disposed in the fixed space portion 12 because
certain sub-
components, e.g., a bath tub, plumbing, or countertops are substantially rigid
and difficult
to compress. Conversely, the passive space portion 14 includes a living room
area 60, a
storage area 62, and a dining area 64. These areas are, by and large, empty
until filled with
futniture and are easily compressed.
In a further embodiment, as shown in Figure 8, some minor but practical and
mechanically novel efficiencies may be attained by multifunction walls 70. A
multi-
function wall 70 includes additional foldable panels 18 that may expand beyond
a simple
flat wall. As shown, the multifunction wall 70 includes a U-shaped portion 72
structured
to be used as a closet, and back wall 74, that may, for example, support a
computer hutch
76. Different functionalities notwithstanding, in this preferred embodiment
this center
wall partition performs quadruple duty as partition, doorway/door, entry
closet and
organizer computer hutch. A further use of multifunction walls 70 is any
function of
mechanically advantageous detail than can be designed and engineered to be
built to
provide user functionality between typical stud walls. During shipping,
multifunction
walls 70 are structured to fold into substantially open spaces in the fixed
space portion 12,
such as the kitchen area 54.
As noted above, a core module 11 by itself is not a complete house or building
but
must be adjoined to other modules 10 in the system for completion. Figures 9A-
9K show
the stages of constructing a substantially complete prefabricated house 3
comprised of two
modules 10, a core module 11 and a roof module 80, as well as roof supports
90. Figure
9A shows the prefabricated house 3 on a truck 7. Figures 9B-9F show the
expansion of
the core module 11 from the first, closed position to the second open position
as described
above in relation to Figures 3-7. As shown in Figure 9G, the roof supports 90
are coupled
to the core module 11 above the first and second roof panels 31, 32. As shown
in Figures
9H-9J, the roof module 80 includes a plurality of foldable panels 18 and at
least one multi-
frame opening 20. The roof module 80 is shown in a first, closed position in
Figure 9H, an
intermediate position in Figure 91, and a second, open position in Figure 9J.
The roof
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module 80 is coupled to the core module 11 and roof supports 90 as shown in
Figure 9K to
form the smaller prefabricated house 3A. Figure 9F shows the core module 11
with a
center staircase 35 to accommodate simpler unfinished second floors as opposed
to the
finished embodiment shown, for example, in Figure 7.
As shown in Figure 10, an alternative core module 11A utilizes all of the
practical
novelty above yet removes the fixtures from within the fixed space portion 12.
In the
alternative core module 11 A, the fixed space portion 12 includes a rigid
storage area 62.
The passive space portion 14 may include a single foldable panel 18 that is a
hinged wall
38. Thus, when the alternate core module 11A is expanded, the openable volume
can
reach 66 foot x 25 foot x 10 foot (interior) and may be used for, but not
limited to, great
rooms, conference, halls, studios, garages (no floor) or other
functionalities.
As shown in Figure 11, another alternative core module 11 B is structured as a
second floor bedroom module 110. Again, the alternative core module 11B
includes a
fixed space portion 12, that includes an opening for a stair well 112, a
hallway 114 and a
bathroom 116, as well as a passive space portion 14 having a plurality of
foldable panels
18, in this instance hinged walls 38. When the hinged walls 38 are moved into
the second,
open position as shown in Figure 11, a plurality of rooms are formed. While
the rooms
may serve any purpose, the rooms are sized to be bedrooms 118. As an example
of the
flexibility of the prefabricated house system 1, it is noted that the
alternative core module
11B may be coupled on top of the core module 11 shown in Figure 7.
Alternatively, the
core modules 11, 11B may be coupled side by side. To do this, the stairwell
opening 112
has a floor installed (not shown) thereby extending the hallway 114. In this
configuration,
the alternative core module 11 B may be coupled to the side of the core module
11 shown
in Figure 7. That is, the alternative core module 11B could be rotated 180
degrees from
the orientation shown in Figure 11, and the multi-frame opening 20 adjacent to
the hallway
114 may be coupled to the multi-frame opening 20 in the living room area 60.
This
functionality is detailed below. Additional elements in Figure 11 are defined
as follows:
A: Master bed 16"2' x 11"4'
B: Bed 2 10"8' x 11"4'
C: Bed 3 14" x 9"2' - Closet 5"6'
D: Bath 5"8' x 10"
E: Ha113"6' and 4"6' wide - Doors a1130" - Floor footprint 43" x 16"6', 709
sq.ft.
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F: Closet 8"8'
G: Closet 6"S'
H: Closet 5"6'
The alternative core module 11B may also include a roof section 130, as shown
in
Figures 12A and 12B. The roof section 130, in the closed position is stored in
a three-
section panel. The front and rear longitudinal side walls are chamfer cut 132
and with a
lower aspect in regard to their adjoining side wall. Additionally, the
alternative core
module 11B demonstrates an alternate and preferred miter hinge design 134
whereby a lap
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joint with overlap is created via the simple expedient of a detail saw cut,
evidenced in
other hinges on this floor plan as well, mechanically stronger and a better
design to prevent
water, wind and weather ingress, and HVAC egress.
Connectivity of the adjacent modules 10 is accomplished by the multi-framed
openings 20. Multi-frame openings 20 are the frames within the modules 10 that
may or
may not be visible from the exterior/interior of the module 10. That is the
multi-frame
opening 20 may be disposed within any wall. For example, a gable end wal191
(Figure
1 A) may appear plain from the inside and out, but in reality a multi-frame
opening 20 is
hidden within the wa1191 and may be framed to accept a window 84 as shown in
Figure 1.
Similarly, a roof panel 81 (Figure 1 A) may appear plain from the inside and
out, but in
reality is hidden framed to accept an exterior dormer 82 as shown in Figure 1.
A front or
rear wall may appear plain but may include multi-frame openings 20 and be
conduited
with appropriate data or an energy cable to accept a front porch or rear deck.
Key
windows are multi-framed so that such openings may be used as doorways to
additional
core modules in larger configurations, but are also framed for other
structures , e.g. a
fireplace 86 (Figure 1). The mechanical, marketing, and cost saving advantages
of multi-
framing are many.
The functionality of multi-frame openings 20 are shown in Figures 13-15. In
Figure 13-15 an embodiment of a prefabricated house 3B includes two different
core
modules 11, 11 A, and two other modules, a first additional module l0A and a
second
additional module IOB. As shown from top to bottom on Figure 13-15, the
modules are
coupled along a their respective longitudinal wall panels 44 in a series as
follows; the first
additional module 10A is coupled to the alternative core module 11A, which is
further
coupled to the core module 11, which is further coupled to the second
additional module
IOB. Each of the different core modules 11, 11A, and first and second
additional modules
10A, lOB have multi-frame openings 20 along their respective lateral walls 45.
A storage
room module lOC having two multi-frame openings 20 is also shown in Figures 13-
15.
The storage room module lOC is shown for the sake of this example, but any
other module
10 having two or more multi-frame openings 20 may be used as well.
As shown in Figure 13, the storage room module lOC is coupled to both the
first
additional module 10A and the alternative core module 11A. As shown, the multi-
frame
openings 20 on the storage room module I OC and on the first additional module
10A and
CA 02442403 2003-09-24
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the alternative core module 11A are aligned. Thus, these multi-frame openings
20 may be
converted to doors, thereby providing access between the first additional
module 10A, the
alternative core module 11 A and the storage room module I OC. The multi-frame
openings
20 on the core module 11 and the second additional module l OB may either be
covered
S with dry wall 19 or used as windows 84.
Another person, however, may wish to have a similar prefabricated house 3B,
but
with the same sized storage room module lOC coupled to different modules 10.
Thus, as
shown in Figure 14, the storage room module I OC is coupled to the alternative
core
module 11 A and the core module 11. Because the multi-framed openings 20 are
distributed in a predetermined mathematical pattern, the multi-frame openings
20 on the
storage room module I OC are also aligned with the multi-frame openings 20 on
the
alternative core module 11A and the core module 11. Similarly, as shown in
Figure 15,
yet another person may wish the storage room module I OC to be coupled to the
core
module 11 and the second additional module l OB. Again, the multi-frame
openings 20 of
each module align with each other. When a multi-frame opening 20 is not
aligned with
another multi-frame opening 20 on another module 10, the unaligned multi-frame
opening
may remain covered or may be used as a window, or a door to the outside.
A similar use of modules 10, specifically a core module 11 and alternative
core
module I IA, each with multi-frame openings 20 is shown in Figures 16 and 17.
20 As shown, in Figure 16, the core module 1 I and alternative core module 11A
are coupled
along their longitudinal walls 44 with the multi-frame opening 20 at about the
middle of
each longitudinal wall 44 acting as a door. The multi-frame openings 20 along
the lateral
walls 45 may be covered, act as windows, or as doors to the outside. In Figure
17, the
lateral wall 45 of the core module 11 is coupled to the longitudinal wall 44
of the
alternative core module 11A. Thus, the multi-frame opening 20 on the lateral
wall 45 of
the core module 11 and the multi-frame opening 20 on the longitudinal wall
pane144 of
the alternative core module I 1 A act as doors. Thus, it can be seen that the
use of multi-
frame openings 20 allow the modules 10 to be disposed in different
configurations relative
to each other to please various customers, while be manufactured in an
efficient, identical
manner.
Other elements and details enhance the functionality and manufacturability of
the
prefabricated house 3 and modules 10. It is well-known that even a more modest
double
CA 02442403 2006-10-11
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wide house still requires a substantial amount of work prior to completion
after it arrives
on the building site. For example, walls must be opened, refinished painted,
spackled,
carpets need to be installed, doorways require a tremendous amount of finish,
as do many
mating surfaces. It is the function of the preferred embodiment to eliminate
the majority
of on-site finishing by pre-organizing, or finishing many items at the
factory. Through this
end it is the intention that the total assets embodied within the invention,
will so lower site
work that there will be little time or money required for final hook up repair
and clean up,
a substantial and many times hidden cost in the industry.
For example, as shown in Figure 18, a floor panel 36 includes a recess 120
structured to accommodate carpeting. As such, carpet is pre-installed where
required in
combination within the exact layout of foldable panels 18. The entire carpeted
floor area
is recessed in the floor between 1/8 inch and one inch depending on carpet to
ensure that
any foldable panels 18 do not bind. Foldable panels 18 may have wheels at
their lowest
lead sweeping corner to aid in opening. As shown in Figure 19, where a floor
panel is
folded back upon itself, a pipe 122 of appropriate diameter and material may
be placed at
the internal crease of the carpet 122A so as to prevent permanent creasing
during
manufacture, storage and shipping.
Floor molding tends to be in compactable structure. In the preferred
embodiment
the hinge 133, described previously, has its true radial center 44C at the
bottom of the
baseboard trim, as shown in Figure 20. As shown in Figure 21, the joint
between a floor
pane136 and a wall panel, e.g., the longitudinal wall panel 44, may further
include
insulation 140.
Another time intensive installation procedure is required for the crown
molding.
Crown molding is used for the mechanical function of creating a separate air
volume for
corner area heat insulation. Crown molding as a means covering seams without
paint and
adding value through better quality. In the prior art, time, labor and cost
were increased
during the finishing of trim. The problems of finishing are four-fold. First,
the trim must
be applied normally by tacking into place creating a hole. Second, any small
gap creates a
thin black gap that the eye is instantly drawn to, so this gap must be
caulked, typically in a
color that matches neither the wall nor the trim accurately, ruining both.
Third, the wall
must be repainted at the cornice edge, often resulting in the entire wall
being re-painted for
practical reasons. Fourth, the cornice must be painted to cover both the tack
holes holding
CA 02442403 2003-09-24
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it on and to cover the caulk on the trim side. These problems are avoided by
the present
invention which provides crown molding, shown in Figure 22, that includes, but
not
limited to, molding 150 having a color matched gasket 152 at its perimeter
molded on, or
adhered on subsequent to production. Presuming a commonly used synthetic
molding of
extruded crown molding, or as a less preferred embodiment, wood. A screw 154
and plug
fastening system with a decorative detail that covers the screw, allowing the
unit to be pre-
colored at the factory, in conjunction with a self-color gasket applied by any
conventional
means. A similar system is applied to all floor/crown/window/door and surround
details
including but not limited to any form of interior wall floor or ceiling trim,
including wall
corner, wall ceiling and wall floor molding, both internal and external to the
home.
Another problem in the prior art was painting the visible seam in the roof
between
ceiling panels. As shown in Figure 23, this is resolved by applying a
decorative grid
pattern covering 160 to the ceiling. This covering 160 also called a coffered
ceiling and
seen as an expensive addition. The covering 160 is inexpensive to install at
the factory
relative to the alternate (and variable cost) at site work. Using the same
technology as the
corner molding as a preferred optional but alternately traditional wood or
suitable synthetic
strips to create the ceiling, the relevant strip which would cover the seam in
the ceiling is
shipped loose and with the simple install of this one small piece the ceiling
is complete
without mess. Gasket sealing, in the preferred embodiment, is foreseen in
order to build to
the widest acceptable tolerances, to lower costs and to improve the speed of
production.
Gasketing may be installed on all leading edges to be bolted or secured
together.
In concert with, or independently of, the preferred embodiment may in addition
to
the gasket seam have an aligning dove tail, lap joint or any irregular surface
to hinder
ingress and egress of rain heat, etc. For the purposes of insulation and
improved quality
and feel, the preferred embodiment may employ a novel foam filling of the back
of the
vinyl clap board. This is believed to be the best mechanical method to get
both a firm feel
to the touch like real clapboard, with a minimum of material and have the
ancillary but
nevertheless valuable benefit of high "r" rated insulation. Corner seam
boards, made from
extruded vinyl, as a preferred embodiment or alternately cast, natural or any
covering
board, to cover both vertical and horizontal core module to core module seams,
are similar
to the interior crown moldings. A variety of exterior finishes both real and
composite,
including but not limited to clapboard, brick, stucco, limestone, stone may be
used.
CA 02442403 2003-09-24
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A common problem with any house is that utilities, wiring ducting alarms and
others are not complete. This problem is addressed by the present invention
via flexible
ducting 170 shown in Figure 24. Using fixed space portions 12 and passive
space
portions 14 assures that wet and pressure pipes (water and gas) not only run
in fixed non
movable locations, i.e., the fixed space portion 12, wet and pressure ducting
is considered
too dangerous or leak prone to run through flexible conduits. The remaining
wire and air
conduits, typically include but are not limited to: electricity, cable, phone,
computer
network cables and other assorted electronic wiring as well as forced air both
hot and cold,
are free to run through the passive fold down spaces via the fold down walls
with a couple
of safety provisions. For air, a simple flexible ducting 170 is employed
between the two
rigid members in the wall. The flexible ducting 170 is of a profile including
but not
limited to round and durometer (hardness) that it resists flexing or is built
to resist flexing
by some other means, including but not limited to a steel coil, for example.
For air conduits, there may be excess conduit when a foldable wall is in the
closed
position. To accommodate the extra length, the conduit resides within about 16
inches on
center frame lumber or steel of the interior wall. For wire cabling, the
cabling is simply
routed through a flexible ducting 170 as is used for air with the same
desirous result. In a
preferred embodiment, access to the services provided by the various conduited
walls can
be via outlets 182 affixed to recess in the baseboard 180, whether they be
vent grills,
electrical outlets or computer cabling, see Figure 25, including
sound/surround sound, etc.
Notwithstanding the above, all wire and air may also be routed routinely if
desired to
emerge from the floor using the flexible non-crushable conduit connector, for
example, it
is oftentimes where there is a coffee table in the middle of the room where a
telephone
might reside but for a telephone wire. Using these elements, the modules
include
substantially finished trim.
As shown in Figure 1, the modules may also include a deck and/or porch modules
10D, 10E, which may also be folded. The folded deck module 10D and exterior
surfaces,
specifically the front porch module 10E, rear porch and second story
balistrading are
structured to be coupled to other modules 10 of the prefabricated house system
1 at
standardized connection points. Standardization of connection points allows
for
standardization of decks, porches or similar outdoor structures, which in turn
allows mass
production, which in turn of course enables mass production and all related
savings. The
CA 02442403 2003-09-24
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invention of a standardized building system that builds flexible prefabricated
houses 3, 3A
designs allows decks to be manufactures in a factory, with the innovative step
of applying
hinges folded flat and shipped cost effectively. Exterior modules 10 may
include, but are
not limited to, a fold down front porch 10E, a fold down front porch with
roof, a fold down
front porch with roof and screens, a fold down front porch with roof and glass
or any
combination of the above with any combination of, cabling for electrical,
sound, bug
zappers, lights and bar-b-q. All decks include multi-framed openings 20 so
that the deck
may be coupled to the housing modules. Similarly, a fold down rear deck module
IOD, in
any number of practical sizes and plan view silhouette, including but not
limited to straight
curved wavy etc., with or without any combination of: cabling for electrical,
sound, bug
zappers, lights and bar b q. may be multi-framed to be attached to an existing
house 3.
While specific embodiments of the invention have been described in detail, it
will
be appreciated by those skilled in the art that various modifications and
alternatives to
those details could be developed in light of the overall teachings of the
disclosure.
Accordingly, the particular arrangements disclosed are meant to be
illustrative only and
not limiting as to the scope of invention which is to be given the full
breadth of the claims
appended and any and all equivalents thereof.
