U.S. patent application number 10/352722 was filed with the patent office on 2003-08-28 for prefabricated housing components.
Invention is credited to Christensen, William R..
Application Number | 20030159366 10/352722 |
Document ID | / |
Family ID | 27760410 |
Filed Date | 2003-08-28 |
United States Patent
Application |
20030159366 |
Kind Code |
A1 |
Christensen, William R. |
August 28, 2003 |
Prefabricated housing components
Abstract
A prefabricated housing component that includes at least one
casting having a wall portion, a floor portion, a ceiling portion,
wherein the wall portion, floor portion and ceiling portion
cooperate to form an interior space, and a cabinet portion
including a recessed portion within the interior space. The
prefabricated housing component further includes a framework
surrounding the casting, wherein the framework provides structural
rigidity thereto.
Inventors: |
Christensen, William R.;
(West Olive, MI) |
Correspondence
Address: |
PRICE HENEVELD COOPER DEWITT & LITTON
695 KENMOOR, S.E.
P O BOX 2567
GRAND RAPIDS
MI
49501
US
|
Family ID: |
27760410 |
Appl. No.: |
10/352722 |
Filed: |
January 28, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60359403 |
Feb 23, 2002 |
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Current U.S.
Class: |
52/79.1 |
Current CPC
Class: |
E04H 1/125 20130101;
E04B 1/34869 20130101 |
Class at
Publication: |
52/79.1 |
International
Class: |
E04H 001/00; E04H
003/00; E04H 005/00; E04H 009/00; E04H 014/00 |
Claims
The invention claimed is:
1. A prefabricated housing component, comprising: at least one
casting, comprising: a wall portion; a floor portion; a ceiling
portion, wherein the wall portion, floor portion and ceiling
portion cooperate to form an interior space; and a cabinet portion
including a recessed portion located within the interior space; and
a framework surrounding the casting, wherein the framework provides
structural rigidity thereto.
2. The prefabricated housing component of claim 1, wherein the
casting comprises fiberglass.
3. The prefabricated housing component of claim 2, wherein the
casting comprises a resin.
4. The prefabricated housing component of claim 3, wherein the
resin is fire retardant.
5. The prefabricated housing component of claim 1, wherein the
casting comprises plastic.
6. The prefabricated housing component of claim 1, wherein the at
least one casting includes a first casting and a second casting
matable theretogether; and further comprising: an alignment portion
including an alignment pin and an alignment aperture.
7. The prefabricated housing component of claim 1, wherein the
framework is fixedly attached to the casting.
8. The prefabricated housing component of claim 6, wherein the
framework includes at least one stud fixedly attached to the
casting via resin and fiberglass.
9. The prefabricated housing component of claim 7, further
comprising: at least one support rib attached to the exterior of
the casting.
10. The prefabricated housing component of claim 9, further
comprising: at least one bracket securing the at least one support
rib to a stud of the framework.
11. The prefabricated housing component of claim 10, wherein the at
least one bracket is adjustable.
12. The prefabricated housing component of claim 1 further
comprising: at least one support rib attached to the exterior of
the casting.
13. The prefabricated housing component of claim 1, wherein the
castings comprise a stress relieving material encased in layers of
resin and fiber material.
14. The prefabricated housing component of claim 12, wherein the
stress relieving material includes cardboard.
15. The prefabricated housing component of claim 14, wherein the
stress relieving material includes wood.
16. The prefabricated housing component of claim 1, wherein the
floor portion of the casting comprises a rigid core material
surrounded by layers of resin and fiber material.
17. The prefabricated housing component of claim 18, wherein the
core material is wood.
18. The prefabricated housing component of claim 1, wherein a lip
portion of the casting surrounding the recessed portion includes a
layer of wood material.
19. The prefabricated housing component of claim 1, further
comprising: a cabinet insert, wherein the recessed portion of the
cabinet portion is cutout to receive the cabinet insert.
20. The prefabricated housing component of claim 22, wherein a lip
portion of the casting surrounding the recessed portion is hook
shaped, and wherein an edge of an insert received within the
recessed portion is hook shaped, such that the lip portion of the
casting and the edge of the insert interlock.
21. The prefabricated housing component of claim 1, wherein the
floor portion is recessed for receiving a flooring material.
22. The prefabricated housing component of claim 1, wherein the
composite casting further comprises a feature selected from a group
consisting of a light mount recess, a sculpted edge, a sculpted
joint and a sculpted corner.
23. The prefabricated housing component of claim 22, wherein the
sculpted edges, sculpted joints and sculpted corners comprise
rounded edges, rounded joints and rounded corners.
24. The prefabricated housing component of claim 1, further
including: a trolley assembly detachably connected to the housing
component and adapted to rollably support the housing
component.
25. The prefabricated housing component of claim 1, further
including: a drain pan attached to the floor portion and adapted to
collect water that leaks through the floor proximate the drain
pan.
26. A method of manufacturing a prefabricated housing component
comprising the steps of: applying a composite material to a mold
that includes a wall portion, a ceiling portion and a floor
portion; allowing the composite material to at least partially
cure, thereby resulting in a casting; removing the casting from
within the mold; inserting the casting into a cavity as defined by
a framework; and securing the casting to the framework.
27. The method of manufacturing a prefabricated housing component
of claim 24, further comprising: securing a support rib to an
exterior of the casting prior to inserting the casting.
28. The method of manufacturing a prefabricated housing component
of claim 27, further comprising: securing the rib to the
framework.
29. The method of manufacturing a prefabricated housing component
of claim 28, wherein the step of securing the rib to the framework
includes securing the rib to the framework with an L-shaped
bracket.
30. The method of manufacturing a prefabricated housing component
of claim 29, wherein the step of securing the rib to the framework
is accomplished prior to the composite material fully curing.
31. The method of manufacturing of a prefabricated housing
component claim 26, wherein the step of applying a composite
material comprises applying corrugated cardboard to the mold.
32. The method of manufacturing a prefabricated housing component
of claim 26, wherein the step of applying a composite material
comprises applying balsa wood to the mold.
33. The method of manufacturing a prefabricated housing component
of claim 26, wherein the mold defines a recessed portion within an
interior of the casting.
34. The method of manufacturing a prefabricated housing component
of claim 33, further including: cutting out a portion of the
recessed portion, thereby forming an aperture within the recessed
portion; providing an insert portion; and inserting the insert
portion into the aperture within the recessed portion.
35. The method of manufacturing a prefabricated housing component
of claim 26, wherein the step of securing the casting to the
framework comprises bonding the framework to the casting with a
composite material.
36. The method of manufacturing a prefabricated housing component
of claim 26, further including: supporting the framework by at
least one trolley assembly, thereby providing clearance below the
housing component.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional
Patent Application No. 60/359,403, filed on Feb. 23, 2002, entitled
PREFABRICATED HOUSING COMPONENTS.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the housing industry and,
in particular, to prefabricated components such as bathrooms and
kitchens which are preferably built at a factory and shipped to a
build site.
[0003] The housing construction industry is one of the largest
sectors of the United States economy. In the construction industry
there is considerable competition to continually produce an
improved product, reduce costs, and speed construction. One way for
a builder to reduce costs is to purchase less expensive materials.
However, this approach often leads to an inferior product or
building. Another approach to reducing costs is to reduce the
amount of labor required to produce a house or building. This is
accomplished by the use of continually improving tools such as nail
guns, power tools, and the like. Labor is also reduced by the use
of ready to install, standardized, or pre-ordered moldings, wall
panels, trusses, floorings, trim, and the like. However, labor
continues to be a significant cost of a house or building.
[0004] One aspect of the labor costs is associated with the
electrical and plumbing work that must be done on site. The
electricians and plumbers are skilled at their craft, but may cause
a delay if they are not able to perform their work under a schedule
desired by the builder. Further, government inspectors may be
required to inspect the electrical and plumbing work before the
drywall or other work can continue. Thus, delays or possible
problems may delay construction and increase costs.
[0005] Another aspect of the construction industry is to increase
the value and desirability of a building by including innovative,
attractive, and more durable features. The continuing goal,
therefore, is to find ways to reduce costs, increase durability and
functionality, improve the aesthetic appeal, and improve
efficiency.
SUMMARY OF THE INVENTION
[0006] To address the goals stated above and other goals, the
inventive prefabricated housing components are manufactured using
large-scale composite molding techniques to form wall, ceilings,
floors, cabinets, and other features from a single casting. In the
preferred embodiment, an entire room, such as a bathroom or a
kitchen, is formed from only two such castings. The two castings
are mated together and aligned with alignment pins to form a single
unit. Support ribs are attached to the exterior of the casting. A
framework, preferably made of wooden or metal studs, is constructed
to enclose the casting. The casting is placed inside of the
framework and the support ribs secure the casting to the framework
while the casting continues to cure. The studs are then more
securely attached to the casting by use of a composite material,
mechanical fasteners and structural components, thereby increasing
the structural resiliency and rigidity of the final structure.
[0007] Various portions of the casting are cutout to provide
apertures for such things as medicine cabinets, towel cabinet
drawers and doors, vanity doors and doors, plumbing access and
electrical devices and switches. The component is then finished by
connecting plumbing and electrical devices, adding doors, and
drawers, installing flooring, sinks, counter tops, towel racks, and
the like to complete the component.
[0008] The component is then shipped to the building site where the
component is installed in place. The high strength of the component
reduces the chance of damage during the shipping process. The
plumbing and electrical work is done at the factory where it is
also inspected. The work is completed indoors and can therefore be
done efficiently regardless of outside weather conditions.
[0009] Finally, the unique construction technique of the invention
permits aesthetically pleasing and useful shapes and designs that
are not typically available using conventional construction
techniques. For example, the molded construction technique permits
the application of various curves and sculptured shapes.
Rectangular cabinets and 90.degree. corners may be replaced with
smoothly sculptured cabinets and rounded comers. The possibility of
designs is virtually limitless.
[0010] In some applications, an additional casting may be used when
it is not practicable to use only two castings. For example, in a
bathroom application, a tub/shower casting may be molded separately
and installed into the component after the initial two halves are
assembled.
[0011] One aspect of the present invention is to provide a
prefabricated housing component that comprises at least one casting
including a wall portion, a floor portion, a ceiling portion,
wherein the wall portion, floor portion and ceiling portion
cooperate to form an interior space, and a cabinet portion
including a recessed portion located within the interior space. The
prefabricated housing component further includes a framework
surrounding the casting, wherein the framework provides structural
rigidity thereto.
[0012] Another aspect of the present invention is to provide a
method of manufacturing a prefabricated housing component that
includes the steps of applying a composite material to a mold that
includes a wall portion, a ceiling portion and a floor portion,
allowing the composite material to at least partially cure, thereby
resulting in a casting, and removing the casting from within the
mold. The method further includes inserting the casting into a
cavity as defined by a framework, and securing the casting to the
framework.
[0013] It is clear that the invention is a significant improvement
over the prior art systems. Additional features and advantages of
the invention will be set forth in the detailed description which
follows, and in part will be readily apparent to those skilled in
the art from that description or recognized by practicing the
invention as described in the detailed description which follows,
the claims, as well as the appended drawings.
[0014] It is to be understood that the foregoing description is
exemplary of the invention only and is intended to provide an
overview for the understanding of the nature and character of the
invention as it is defined by the claims. The accompanying drawings
are included to provide a further understanding of the invention
and are incorporated and constitute part of this specification. The
drawings illustrate various features and embodiments of the
invention which, together with their description serve to explain
the principals and operation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a cutaway top perspective view of a casting
embodying the present invention, wherein the casting comprises a
bathroom;
[0016] FIG. 2 is a front elevational view of a vanity, a medicine
cabinet, and a towel cabinet of the bathroom of FIG. 1;
[0017] FIG. 3 is a top plan view of the bathroom of FIG. 1;
[0018] FIG. 4 is a top plan view of a recessed portion and an
insert cut away to show an interlocking joint;
[0019] FIG. 5 is a front elevational view of the recessed portion
of the casting;
[0020] FIG. 6 is an exploded perspective view of the castings and
framework associated therewith;
[0021] FIG. 7 is a cross-sectional side elevational view along
section VII-VII, FIG. 1;
[0022] FIG. 8 is a top perspective view of a stud, a support rib,
and a bracket according to the invention;
[0023] FIG. 9 is a top perspective view of an insert according to
the invention;
[0024] FIG. 10 is a cross-sectional side elevational view of an
alignment pin and an associated flooring;
[0025] FIG. 11 is a cross-sectional top plan view of a wall of the
casting;
[0026] FIG. 12 is a cross-sectional view of a strengthened portion
of the casting;
[0027] FIG. 13 is a cross-sectional view of the floor and the wall
of the casting;
[0028] FIG. 14 is a top plan view of an alternative casting of the
present invention, wherein the alternative casting comprises a
kitchen;
[0029] FIG. 15 is a cross-sectional side elevational view of a
lower drain pan;
[0030] FIG. 16 is a top perspective view of a bath/shower
casting;
[0031] FIG. 17 is a side elevational view of the housing component
supported by a trolley assembly; and
[0032] FIG. 18 is a perspective view of the trolley assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Reference will now be made in detail to the present
preferred embodiments of the invention, examples of which are
illustrated in the accompanying drawings. Wherever possible, the
same reference numerals will be used throughout the drawings to
refer to the same or like parts.
[0034] An exemplary embodiment of a prefabricated housing component
according to the present invention is shown in FIG. 1, and is
designated generally throughout by reference numeral 10. Parts of
the prefabricated housing component 10 of the present invention
will first be briefly described and then described in detail. The
most common use for the invention is as a bathroom or kitchen for a
home, a duplex, an apartment, a hotel, and the like. However, those
skilled in the art will appreciate that the invention may be
adapted for other applications as well. The following discussion
will describe the invention in relation to a bathroom
application.
[0035] As illustrated in FIG. 1, prefabricated housing component 10
comprises a first casting 11A, a second casting 11B and an external
framework 12. The castings 11A and 11B are formed into a vanity
cabinet 13A, a towel cabinet 13B, a medicine cabinet 13C and a
light bar 13D. Other parts of the construction comprise walls 14A,
a ceiling 14B, and a floor 14C. The castings 11A and 11B are
constructed out of fiberglass or composite type materials. The
invention may also be practiced with other types of materials such
as plastics which may be molded. The fiberglass construction
comprises multiple layers of flame retardant resin and glass fibers
with a colored gel layer as the finishing layer. A strengthening
material, or core material, is included inside the layers of resin
and glass fibers. Preferably, this material is a quarter inch layer
of wood, and preferably balsa wood. Some portions of the
construction include stronger strengthening layers such as 1/2 inch
plywood. Such strengthened portions are used, for example, where
drawers or cabinet doors are attached. The two castings 11A and 11B
are aligned and attached together using an appropriate
adhesive.
[0036] The interior of the component is finished by cutting
openings in the casting 11A for the drawers, cabinetry doors, light
bar assemblies, and pluming and electrical connections.
Conventional doors, drawers, countertops 15A, sinks, faucets,
toilets 15B, bath tubs 15C, lights, and electrical outlets 15D are
attached or installed in a conventional manner.
[0037] One aspect of the invention is that once a mold (not shown)
is formed or constructed, castings may be made quickly and easily
from such mold. The first step in constructing the mold is to
construct a female plug (not shown) in the shape of the desired
casting such as castings 11A and 11B. The plug is virtually
identical in shape to the casting 11A but without the added
hardware, faucets and sink. The plug is preferably made of wood and
is primed and waxed to a smooth surface. A male mold (not shown) is
made from the plug in a conventional manner and the female castings
are then created by placing multiple layers of fiberglass
surrounding a wood layer on the mold. The casting, such as casting
11A and 11B is removed from the mold and inserted inside of the
framework 12. A plurality of support ribs 16A are secured to the
casting 11A or 11B prior to placing the casting 11A or 11B into the
framework 12. The ribs 16A are secured to a plurality of studs 16B
of the framework 12.
[0038] The electrical and plumbing is completed on the component 10
in the factory and is inspected to meet the required building
codes. The plumbing and electrical are of a conventional nature,
however, a preferred embodiment includes utilizing electrical
harnesses and systems that are configured to minimize the number of
electrical and plumbing connections required to be made at the
construction site.
[0039] Other aspects of the invention include curved or sculptured
portions of the castings 11. Because of the manufacturing technique
used, atypical shapes may be introduced into the castings. For
example, rounded corners 17 may be used extensively. Other portions
may also be curved or contoured surfaces, including cabinetry,
walls, floors, and ceilings to provide an appealing, innovative and
upscale appearance. The atypical shapes may also be used to provide
improved utility such as improved ergonomics, more usable storage
and safety features
[0040] FIG. 2 is a front view of the finished cabinetry of FIG. 1.
Shown in FIG. 2 are the lights 21, electrical outlets 15D,
electrical switches 22, medicine cabinet mirror doors 23, towel
holders 24, drawers 25 and cabinet doors 26. The medicine cabinet
13C and the towel cabinet 13B are typically each provided with
shelves 27. To provide shelves 27 and to provide an aesthetically
pleasing and useful interior, an insert is provided which is
secured into the interior of the medicine cabinet 13C and the towel
cabinet 13B.
[0041] FIG. 3 illustrates a cutaway top view of the castings 11A
and 11B. Shown in the figure is the vanity top 31, sink 32 and
faucets 33. A pair of alignment pins 34 are shown along a seam 35
located between the castings 11A and 11B. Alignment pins 34, or
other alignment devices, are utilized to keep the edges of the
castings 11A and 11B aligned with one another while the castings
11A and 11B are bonded together. The alignment pins 34 save time
and reduce the risk of misalignment or imperfections in
alignment.
[0042] As illustrated in FIG. 3, the lips 36 of the cabinetry 13B
and 13C where a drawer 25 or door 26 are attached are preferably
reinforced with a rigid reinforcement material, such as 1/2 inch
plywood and the like. As mentioned above, the castings 11A and 11B
are preferably reinforced with 1/4 inch balsa wood bonded inside at
least two layers of fiberglass.
[0043] The apertures for the drawers 25, the towel cabinet 13B and
the medicine cabinet 13C are cut from the original casting 11A. The
mold if formed to create recessed portions in the casting 11A so
that it is readily apparent where the cuts are to be made. FIGS. 4
and 5 illustrate a cutout line 51 and a preferred water resistant
joint 40 for use with an insert 41, such as the drawers 25 and the
cabinets 13B and 13C. The casting 11A is first cut along the edge
of the recessed portion 50 as illustrated by the cutout line 51.
The lip 36 of the recessed portion is preferably reinforced with
1/2 inch plywood, or other suitably functioning reinforcing
material as discussed above, for securing and mounting the drawers
25 and doors 23 and 26. The inserts 41 are sized to fit within the
aperture 52 created by cutting along the cutout line 51. The edges
of the insert 41 and the edge of the aperture 52 form the
interlocking water resistant joint 40 to securely hold the insert
41 within the aperture 52. Adhesive is applied to the joint 40 for
added strength and water resistance. Inserts 41 are preferably
utilized to create the towel cabinet 13B and the medicine cabinet
13C.
[0044] Another aspect of the housing component 10 according to the
invention is the framework 12 into which the castings 11A and 11B
are inserted. The framework 12 is constructed according to approved
building standards and is preferably constructed of a plurality of
studs 12B, such as 2.times.4's and the like. Because the framework
12 is assembled at the factory, it reduces the framing required to
be done at the construction site and saves time and money. In a
preferred embodiment, the housing component 10 is shipped on a
plurality of castors (not shown), thereby allowing the builder to
merely lower the completed component to the correct floor within
the building, roll the component 10 to the desired location, and
secure the component 10 to the associated sub-floor.
[0045] In assembly, the castings 11A and 11B are aligned with the
alignment pins 34 and secured within the support ribs 16. The
support ribs 16 are bonded to the exterior of the castings 11A and
11B and are preferably made of furring strips (e.g., wood strips)
of approximately 1 inch by 3 inches.
[0046] The framework 12 is constructed such that a sidewall 12C is
separated from the framework 12 until the castings 11A and 11B are
inserted into a framework aperture 12C. Once the castings 11A and
11B are in place, the sidewall 12A is attached to the balance of
the framework 12.
[0047] The castings 11A and 11B are then secured to the framework
12 via a plurality of metal brackets 71 (FIG. 8), as shown in FIG.
7. The brackets 71 are L-shaped brackets with oval apertures 71A
extending therethrough to provide for adjustment as the nail or
screws secure the brackets 71 to the studs 12B. Each bracket 71
attaches to both the rib 16 and the stud 12B. The oval apertures
71A in the bracket 71 provide adjustment as needed. By using the
technique of adjustably securing the castings 11A and 11B to the
framework 12, the castings 11A and 11B are able to be assembled to
the framework 12 while the castings 11A and 11B complete the curing
process. This design allows for higher throughput by reducing the
cycle time required to create each casting 11A and 11B. Preferably,
using the adjustable technique, permits the castings 11A and 11B to
be removed from the mold in approximately 1/2 the time required to
attain a fully cured casting. In other words, the productively of
each mold is doubled.
[0048] In assembly, alignment pins 34 are located about the
circumference of the castings 11A and 11B. However, once the
castings 11A and 11B are adhesively bonded, the alignment pins 34
located near the floor 14C are ground off or cut off to provide a
level floor surface.
[0049] For greater strength, the studs 12B of framework 12 are then
"glassed" i.e., bonded with the composite material 72, to the
exterior of the castings 11A and 11B. The bond 72 extends along the
entire length of studs 12B. This construction makes the overall
component 10 very strong. The strength of the completed component
10 is contemplated to make it the strongest room of a construction.
Therefore, it may also provide improved safety from storms,
earthquakes, or similar dangerous conditions. It is also unlikely
to be damaged or cracked during shipment to the construction
site.
[0050] As illustrated in FIG. 9, the insert 41 of the medicine
cabinet 13 includes adjustable shelving as provided by holes 91A
that support pins 91B for supporting shelves in a conventional
manner. Of course, other types of medicine cabinet units may also
be used with the invention. Similar type shelving construction may
also be utilized within the vanity cabinet 13A and the towel
cabinet 13B.
[0051] The floor 14C of the castings 11A and 11B is illustrated in
FIG. 10. The alignment pin 34 is no longer need after the castings
11A and 11B have bonded together via an adhesive 102 and the
alignment pin 34 is typically removed. Those of ordinary skill in
the art recognize that various configurations of alignment pins,
grooves or ridges may be utilized with the invention. The floor 14C
of the castings 11A and 11B is preferably covered with a flooring
material 103 that provides the desired color or texture of the
builder, and comprise linoleum, tile and the like. The flooring
material 103 also covers and hides the seam between the castings
11A and 11B.
[0052] Preferably, castings 11A and 11B are each constructed of
multiple layers of fiber glass 111 and epoxy 113 with a colored
layer 112 that provides the finished surface visible to the user.
The colored layer 112 is preferably a gel coating. Sandwiched
between the layers of the fiber glass 111 and the epoxy 113 is a
layer of support material 114. The support material 114 may be
cardboard, corrugated cardboard, wood, or other material that can
provide adequate support. It is also desirable if the material
provides some stress reduction such that the composite materials
can move slightly if stress builds sufficiently. The most preferred
support materials are 1/4 inch bolsa wood for most surfaces, and
1/2 inch plywood for high stress areas such as the lips 36 of the
apertures 52, where drawers or doors attach. An alternative
embodiment utilized a layer of gas trapped between the multiple
layers. FIG. 12 is another illustration of the composite
construction where the support material is wood.
[0053] An example of the contoured surfaces and the curves that are
readily implemented by the use of the invention is illustrated in
FIG. 13, showing a curve 130 from the wall 14A down to the floor
14C. The invention can also accommodate formation of a recessed
portion 131 appropriate for receiving the flooring material
103.
[0054] Those skilled in the art understand that there are some
limitations to the shapes that can be reasonably fabricated using
molds. Accordingly, it is understood that some shapes, such as a
bathtub 150 (FIG. 14) are more easily formed as a separate casting
and then mounted into the appropriate location in the castings 11A
and 11B. In the alternative, various other tub/shower units may be
purchased and installed in the unit in a conventional manner.
[0055] Another aspect of the present invention is to provide a
lower drain pain 170 (FIG. 15) located proximate the bathtub 150,
and adapted to prevent water from leaking pipes associated with the
bathtub 150. It should be noted that while the drain pan 170 is
described in relation to bathtub 150, the drain pan 170 may be
utilized with a multitude of plumbing fixtures and applications. In
the illustrated example, the drain pan 170 includes a housing
member 172 having a peripherally extending attachment flange 174,
and a collar member 175 having a peripherally extending attachment
flange 176. In assembly, the housing member 172 is placed below the
floor of the housing component 10 proximate a location of water
pipes associated with the bathtub 150, such as a drain pipe 178, an
over-flow pipe 180, and the like. The housing member 172 is
connected to the floor of the housing component 10 via a plurality
of mechanical fasteners and caulk. The collar member 175 is aligned
with the housing member 172, and the flange 176 of the collar
member 175 is attached to an upper surface of the floor of the
hosing component 10 via a plurality of mechanical fasteners and
caulk.
[0056] In another aspect of the invention, a kitchen room 140 (FIG.
16) may be implemented with similar advantages as discussed for the
bathroom. Similar to the casting 11A and 11B of the bathroom
component 9, castings 141 of the kitchen room 140 are formed and
bonded together. Inserts such as cabinets and counters 142 are
formed in a similar manner as described above. Locations for
accessories such as sinks 143, ovens 144, dishwashers 145 and a
refrigerator 146 are also provided. The advantages of pre-plumbing
and electrical wiring provide savings similar to the bathroom
component 9 described above.
[0057] As illustrated in FIGS. 17 and 18, a plurality of trolley
assemblies 150 utilized to support the housing component 10 during
the installation process. Each trolley assembly 150 includes castor
wheel 152 connected to an associated stud 16B via s support bracket
154 and mounting hardware. Each support bracket includes a mounting
portion 156 adapted to connect to the stud 16B, and a wheel support
portion 158 integral with and extending substantially orthogonal to
mounting portion 156. The mounting portion 156 includes a plurality
of elongated, longitudinally extending slots 160, and a plurality
of apertures 162, all of which are adapted to receive mounting
hardware such as lugs 164 therein. In assembly, the trolleys 150
are located with respect to the housing component 10 so as to
provide clearance between a sub-floor 166 and the housing component
10, thereby allowing the housing component to be rolled along the
sub-floor 166. The lugs 164 are tightened within the slots 160 to
maintain this clearance. Additionally, the lugs 164 may be placed
within apertures 162, thereby preventing the possibility of the
lugs 164 sliding within the slots 160 and the housing component 10
touching the sub-floor 166. Once the housing component 10 is
delivered to the proper located within the building, the lugs 164
are removed from within the apertures 162 and the slots 160,
thereby allowing the housing component 10 to rest on the sub-floor
166.
[0058] It will become apparent to those skilled in the art that
various modifications to the preferred embodiment of the invention
as described herein can be made without departing from the spirit
or scope of the invention as defined by the appended claims.
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