U.S. patent application number 12/074584 was filed with the patent office on 2009-09-10 for prefabricated containerized housing.
Invention is credited to Joseph Esposito.
Application Number | 20090223143 12/074584 |
Document ID | / |
Family ID | 41052151 |
Filed Date | 2009-09-10 |
United States Patent
Application |
20090223143 |
Kind Code |
A1 |
Esposito; Joseph |
September 10, 2009 |
Prefabricated containerized housing
Abstract
A single, self-contained housing core configured for
containerization is provided. The housing core includes a first
section having a floor and a first portion of walls. A second
section is connected with the first section to define at least one
cavity. The second section includes a ceiling and a second portion
of the walls. The second section also includes a reservoir.
Deployment items are disposed with the first and second sections.
Implants are disposed within the first and second sections. Loose
items are disposed with the first and second sections. Methods and
systems of constructing a dwelling unit including the housing core
and transporting the housing core via intermodal transport are also
disclosed.
Inventors: |
Esposito; Joseph;
(Huntington Bay, NY) |
Correspondence
Address: |
DILWORTH & BARRESE, LLP
1000 WOODBURY ROAD, SUITE 405
WOODBURY
NY
11797
US
|
Family ID: |
41052151 |
Appl. No.: |
12/074584 |
Filed: |
March 5, 2008 |
Current U.S.
Class: |
52/79.1 ;
52/745.19 |
Current CPC
Class: |
E04B 1/35 20130101; E04H
1/1205 20130101; E04H 2001/1283 20130101; E04B 2001/34389 20130101;
E04B 1/34869 20130101 |
Class at
Publication: |
52/79.1 ;
52/745.19 |
International
Class: |
E04H 1/02 20060101
E04H001/02 |
Claims
1. A single, self-contained housing core configured for
containerization, the housing core comprising: a first section
including a floor and a first portion of walls; a second section
connected with the first section to define at least one cavity, the
second section including a ceiling and a second portion of the
walls, the second section also including a reservoir; deployment
items being disposed in the at least one cavity of the first and
second sections; and implants being disposed within the first and
second sections.
2. A housing core according to claim 1, wherein the first and
second sections are fabricated from foam, plastic, wood, steel,
aluminum or recycled waste material.
3. A housing core according to claim 1, wherein surfaces of the
first and second sections are coated with a hard finishing
compound.
4. A housing core according to claim 1, wherein the first and
second sections include corner and/or edge reinforcements.
5. A housing core according to claim 1, wherein the housing core
complies with ISO standards for intermodal freight transport.
6. A housing core according to claim 1, wherein the housing core is
configured for standard containerization of a 20-foot
container.
7. A housing core according to claim 1, wherein the housing core is
configured for stand-alone operation.
8. A housing core according to claim 1, wherein the housing core
includes water conservation components.
9. A housing core according to claim 1, wherein the housing core
includes recycling components.
10. A housing core according to claim 1, wherein the implants
include high pressure laminate floor surfaces, plumbing pipe trees
or receiver fittings.
11. A housing core according to claim 1, wherein the first section
is injection molded.
12. A housing core according to claim 1, wherein the second section
is injection molded.
13. A method for intermodal freight transport of a containerized
housing core, the method comprising the steps of: providing a
single, self-contained housing core, the housing core including a
first section and a second section; injection molding a first
section; implanting components with the first section during
injection molding; injection molding a second section; implanting
components with the second section during injection molding;
joining the first section and the second section to define at least
one cavity configured for disposal of deployment items and loose
items therebetween; disposing deployment items within the at least
one cavity; disposing loose items within the at least one cavity;
transporting the housing core via intermodal freight transport;
releasing the deployment items; installing the deployment items
with the first and second sections; and constructing a dwelling
unit with the housing core.
14. A housing core according to claim 1, wherein the first section
and the second section are vacuum formed.
15. A housing core according to claim 1, wherein the first section
is joined with the second section to define at least one
cavity.
16. A method for intermodal freight transport of a containerized
housing core according to claim 13, further comprising the step of
constructing exterior walls from materials stored within the
housing core to construct the dwelling unit.
17. A method for intermodal freight transport of a containerized
housing core according to claim 13, further comprising the step of
consolidating deployment items in the at least one cavity, whereby
the step of consolidating includes partial installation of the
deployment items and expansion of the deployment items during
construction of the dwelling unit.
18. A housing core according to claim 1, wherein the housing core
has a cross-sectional beam configuration to provide strength.
19. A single, self-contained dwelling unit configured for
containerization, the dwelling unit comprising: a lower half
including a floor and a lower portion of walls; an upper half
joined with a lower half to define a plurality of cavities, the
upper half including a ceiling and an upper portion of the walls;
the upper half also including a reservoir configured for collection
of water; deployment items being disposed in the plurality of
cavities; implants being disposed with the lower half and the upper
half; loose items being disposed in the plurality of cavities,
wherein the lower half and the upper half are joined in an I-beam
configuration; and extension walls being disposed in the plurality
of cavities.
20. A housing core according to claim 1, wherein the first section
and the second section are connected to define a plurality of
cavities.
21. A housing core according to claim 1, wherein the deployment
items are disposed with aligned openings of the first and second
sections.
22. A housing core according to claim 1, further comprising panels
configured to protect the housing core and being removable from the
housing core to form a wall extending from the housing core.
23. A housing core according to claim 1, wherein the housing is
configured for assembly as a dwelling and provides immediate
lateral stability of the dwelling.
24. A housing core according to claim 1, wherein the reservoir is
configured to collect natural elements.
25. A housing core according to claim 1, further comprising loose
items being disposed in the at least one cavity of the first and
second sections.
26. A housing core according to claim 25, wherein the at least one
cavity is configured to support materials for walls, which are
constructed to enclose at least 1,000 square feet of enclosure.
27. A housing core according to claim 1, further comprising
installed components disposed with the first and second
sections.
28. A housing core according to claim 1, wherein the deployment
items include a septic system.
29. A housing core according to claim 1, wherein the housing core
is configured for construction having solid walls at its corners.
Description
TECHNICAL FIELD
[0001] The present disclosure is directed to prefabricated housing
and, more particularly, to a single, self-contained sustainable
housing core configured for intermodal containerization and
transport with related methods for construction of a complete
dwelling and systems, which may utilize unskilled labor to assemble
on site.
BACKGROUND OF THE INVENTION
[0002] Prefabricated housing for dwelling is well known. Some
prefabricated housing modules were factory built and transported to
a local building site via truck trailer. These early housing
modules failed when competing with site built homes due to the
resultant high costs and/or extreme designs. These high costs and
cumbersome transportation methods prevented such prefabricated
housing from reaching other markets, making availability within
reach of only a limited regional market.
[0003] More recent attempts have been made to overcome the
associated high costs with early prefabrication housing in an
effort to compete with conventional homes. These prefabricated
housing systems were designed as wide-load truck size sections,
which were joined on site. These designs suffered from drawbacks
such as the shipping of empty space and the performance of
extensive redundant site work to reconnect the modules and their
associated components. These attempts also disadvantageously failed
to address the issues of very low cost, sustainability and
worldwide distribution of housing units for dwelling.
[0004] These attempts also do not provide a solution to the
worldwide challenges of providing a domicile of shelter and safety
for those in need of a home and especially in underdeveloped
geographies. People living in underdeveloped geographies lack
access to safe drinking water, basic sanitation, and have no access
to grid electricity. In addition, manufactured housing to date has
failed to consolidate demand and as a result are not able to take
advantage of high volume mass production to reduce cost. Such
limited regional use fails to create the necessary demand in volume
to apply high technology solutions to these domicile issues for
those in need. As a result, no known prefabricated manufactured
housing to date has achieved sustainable, off grid power and water
and sanitation in a viable way.
[0005] Intermodal shipping containers bring goods to every corner
of the world. Many cities include shipping ports that have the
capability of handling these standard shipping containers.
Standards are determined by the International Organization For
Standardization (ISO), which is located in Geneva, Switzerland and
publishes the International Standards. For example, five common
container lengths include 20 foot (ft), 40 ft, 45 ft, 48 ft, and 53
ft. The 20 ft container is the most common length worldwide and the
ISO provides International Standards for the 20 foot container. For
example, such published International Standards for the 20 ft
container include volume (1,169 ft.sup.3), maximum gross mass
(52,910 lb), empty weight (4,850 lb) and net load (48,060 lb).
[0006] Containerization is a system of intermodal freight transport
using standard ISO containers. Such shipping containers can be
transported by ship, rail, truck or air. However, due to the
abundant use of these shipping containers, the return and reuse of
these shipping containers has become a drawback.
[0007] Therefore, it would be desirable to overcome the
disadvantages and drawbacks of the prior art with a single,
self-contained housing core configured for containerization and
related methods for construction of a dwelling and systems for
intermodal freight transport thereof. Further, it would be
desirable if the housing core and related methods and systems for
intermodal freight transport provide low cost, sustaining domiciles
of shelter and safety for those in need of a house in various
geographies for worldwide distribution. It is most desirable that
the housing core and related methods and systems of the present
disclosure are advantageously employed to provide an affordable
home that is self-sustaining, and utilizes renewable energy and
conservation techniques such that the home avoids drawing on
non-renewable resources. It is contemplated that such a housing
core includes internet access. It is further contemplated that the
housing core of the present disclosure is easily and efficiently
manufactured and assembled.
SUMMARY OF THE INVENTION
[0008] Accordingly, a single, self-contained housing core
configured for containerization is disclosed with related methods
of construction of a dwelling and systems for intermodal freight
transport thereof, which overcome the disadvantages and drawbacks
of the prior art. Desirably, the housing core and related methods
and systems, provide low cost, sustaining domiciles of shelter and
safety for those in need of a home and in various geographies for
worldwide distribution. The housing core and related methods and
systems may be advantageously employed to provide an affordable
home that is self-sustaining, and utilizes renewable energy and
conservation techniques such that the home avoids drawing on
non-renewable resources or the need to be connected to utility
infrastructure. It is envisioned that the housing core has wireless
internet access and/or land line internet access. It is further
envisioned that the housing core is easily and efficiently
manufactured and assembled.
[0009] It is envisioned that the core includes all the mechanical,
electric and hydraulic systems of the dwelling, as well as the
spaces and fixtures to use these systems. The core needs no
additional work on site for those systems to function. It is
contemplated that the core is a rigid, reinforced structure, which
provides lateral stability to the construction of the dwelling.
This is advantageously enhanced by the construction of a rigid roof
using development items (e.g. wood I-beams and panels). This rigid
flat plane roof is laterally braced by the core and extends lateral
stability to exterior walls. Alternatively, the roof could be a
fabric, suspended between the rigid core and columns or other
structural elements.
[0010] It is contemplated that the housing core configured for
containerization is a transport mechanism for materials required
for the construction of the dwelling.
[0011] In one particular embodiment, in accordance with the
principals of the present disclosure, a single, self-contained
housing core configured for containerization is provided. The
housing core includes a first section having a floor and a first
portion of walls. A second section is connected with the first
section to define at least one cavity. The second section includes
a ceiling and a second portion of the walls. The second section
also includes a reservoir, such as, for example, a water tank.
[0012] Deployment items such as, for example, a roof membrane and
installed components such as, for example, refrigeration units are
disposed in the at least one cavity of the first and second
sections. Implants are disposed within the first and second
sections. The implants may include high pressure laminate floor
surfaces, plumbing pipe trees, electric harness and receiver
fittings, etc. Incidental or loose items such as flooring, for
example, carpet and portland cement, are disposed with the first
and second sections.
[0013] The first and second sections may be injection molded. The
sections may also be manufactured by other methods including vacuum
forming. The first section may be configured as a lower half and
the second section may be configured as an upper half. The first
and second sections may be fabricated from plastic, wood, steel
and/or aluminum. The first and second sections can be coated with a
hard finishing compound so that the wall surfaces are cleanable and
sanitary. The first and second sections may include corner and edge
reinforcements. The housing core may have a cross-sectional I-beam
configuration to provide strength.
[0014] It is contemplated that the housing core complies with ISO
standards for intermodal freight transport. It is further
contemplated that the housing core is configured for standard
containerization of a 20 ft high cube container and/or stand-alone
operation.
[0015] Alternatively, the housing core includes water conservation
components and/or recycling components. Alternatively, the
reservoir is configured to collect natural elements. The housing
core can include loose items being disposed in the at least one
cavity of the first and second sections. The housing core can
include installed components disposed with the first and second
sections. The deployment items include a septic system.
[0016] The at least one cavity is configured to support materials
for walls. The walls are constructed to enclose at least 1,000
square feet of enclosure. The housing core may be configured for
construction having solid walls at its corners.
[0017] The first section and the second section may be connected to
define a plurality of cavities. The deployment items can be
disposed with aligned openings of the first and second sections.
The housing core may include panels configured to protect the
housing core. The panels are removable from the housing core to
form a wall extending from the housing core. The housing core is
configured for assembly as a dwelling and provides immediate
lateral stability of the dwelling.
[0018] In an alternate embodiment, in accordance with the
principles of the present disclosure, a method for intermodal
freight transport of a containerized housing core is provided. The
method includes the steps of: providing a single, self-contained
housing core, the housing core including a first section and a
second section; injection molding a first section; implanting
components with the first section during injection molding;
injection molding a second section; implanting components with the
second section during injection molding; joining the first section
and the second section, which creates at least one cavity
therebetween; disposing deployment items within the at least one
cavity; disposing installed items within the at least one cavity;
transporting the housing core via intermodal freight transport;
installing deployment items with the first and second sections; and
constructing a dwelling unit with the housing core. The method may
include the step of constructing extension walls with the housing
core to construct the dwelling unit. The method may include the
step of consolidating deployment items in the cavity, whereby the
step of consolidating includes partial installation of the
deployment items and expansion of the deployment items during
construction of the dwelling unit. The housing core includes a
manufactured, affordable dwelling, which utilizes renewable energy
and conservation techniques, and can be delivered worldwide.
[0019] In another alternate embodiment, a single, self-contained
dwelling unit configured for containerization is provided. The
dwelling unit includes a lower half having a floor and a lower
portion of walls. An upper half is joined with the lower half to
define a plurality of cavities. The upper half includes a ceiling
and an upper portion of the walls. The upper half also includes a
reservoir. Deployment items are disposed in the plurality of
cavities. Implants are disposed with the lower half and the upper
half. Loose items are disposed in the plurality of cavities. The
lower half and the upper half are joined in an I-beam
configuration. Extension walls are disposed in the plurality of
cavities.
[0020] The housing core is designed to provide the aspects of a
shelter in a package that can be deployed by an unskilled worker,
or an end user of the housing core. The house core can be a
combination of factory built mechanical and electrical systems
coupled with local construction of the shell or enclosure.
[0021] For example, the housing core may include a one kilowatt
system, including one hundred square feet of photovoltaic power, as
is contemplated, to be built into the housing core's structure and
will produce 1200 to 1600 kilo-watt hours (kwh) of power annually.
It is envisioned that such a power supply is sufficient to provide
energy for refrigeration, pumps for water management, light and
internet capability. The need for battery storage can be minimized
by cycling energy use and conservation techniques. Other renewable
power sources can be incorporated when appropriate, such as thermal
and/or solar in regions where heat is needed, and wind
generation.
[0022] The housing core provides a dwelling, which includes rain
harvesting and water management. Even in semi-arid grassland areas,
adequate rainfall can be harvested and stored by the components of
the housing core to get through dry seasons. A rain harvesting area
or water tank of the housing core is contemplated for each unit.
For example, the housing core can include a rain harvesting area,
which is 28 by 44 feet or about 1200 square feet with primary
storage of about 1000 gallons and secondary storage as needed
depending on rainfall and frequency. The water management of the
housing core may include recycling water, specially designed
fixtures, bathing and laundering techniques, etc. Alternatively,
sanitary disposal of waste is achieved by specially-designed
deployment items such as, for example, septic systems.
[0023] The dwelling can provide housing for 4 to 8 persons and
provide at least 25 gallons of water per day. This can be collected
from about 12 inches of rain per year, and this amount can be
supplemented by other methods. Purification methods are well known
and can be implemented with minimal electric power.
[0024] The housing core may be configured to provide dwelling for
rural areas whereby population densities are low. Alternatively,
the housing core may be utilized with areas having densities of 12
housing cores or about 70 people per acre. It is contemplated that
the housing core can include 1200 square feet of living space.
Thus, each core can house a single family, an extended family or
even two families.
[0025] In one embodiment, the housing core is configured as a
one-story structure. The housing core can effectively harvest
rainwater and solar energy, and needs no infrastructure. It is
envisioned that a plurality of housing cores may be employed in
other configurations such as two-story, three-story and/or multiple
story structures. In an alternate embodiment, the housing core(s)
may be utilized for small schools and medical centers. Walls may be
built with indigenous material, which could be customized to fit
specific requirements. Multiple cores could be linked for larger
structures.
[0026] Alternatively, each housing core can be constructed with
compacted earth foundations and floors, and require no centralized
infrastructure. The housing cores can be constructed on
platforms.
[0027] The housing core design utilizes a system of
containerization, which is a component for worldwide delivery. This
advantageous system eliminates disposal or returning empty space.
In one embodiment, the housing core is transported as a 20 ft
container and meets ISO standardized dimensions and specifications.
It is envisioned that the relatively small size of the housing
core, along with its stackable and weatherproof intermodal handling
capabilities, allows stockpiling of multiple housing cores at a
storage facility. It is further envisioned that a plurality of
housing cores, including thousands of units, could be distributed
domestically and throughout the world. For example, such housing
cores can be shipped by relief agencies or to be received by
communities in the process of building.
[0028] Advantageously, the containerized housing core does not
require opening until it reaches its desired transport destination.
Once dispatched to a desired location, or shipped to a
predetermined geography, all portions and/or components of the
containerized housing core are used to complete the housing unit or
dwelling. In one embodiment, an outer protective skin of the
housing core includes panels, which would be removed at the
transport destination. The panels may be used as a roof deck of the
housing core upon which a waterproof membrane is disposed. The
housing can include reinforced structural corners, employed for
shipping and stacking, to form the structure of the housing core.
The core provides rigidity and lateral stability for the dwelling,
which allows for facile on-site assembly. The housing core
configuration provides for no packaging waste, nor any container or
portion thereof to return and/or store. Construction and mechanical
systems, such as photovoltaic systems, including walls
incorporating them, are constructed, assembled and completed prior
to shipping and/or transport.
[0029] Within the containerized housing core, the remaining volume
is packed with prefabricated materials for roof span and water
harvesting. Windows and doors, also packed with the housing core,
are deployed once the housing core is disposed at its desired
location and the dwelling including the housing core is site
constructed. It is contemplated that there is sufficient remaining
space within the housing core, in addition to the deployable
construction materials, to include other appropriate items, such
as, bicycles, tools (for example, mud brick presses and compaction
devices), clothing, sewing machines, bedding, medical items, books,
computers and cellular phones, musical instruments and food. It is
further contemplated that specialized agencies could supply these
items.
[0030] It is envisioned that the containerized housing core meets
the standards of design, and delivers comfort and livability to
users of diverse cultures, economic status and geographic
location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and other objects, features and advantages will
become more readily apparent from the specific description
accompanied by the following drawings, in which:
[0032] FIG. 1 is a perspective view of a containerized housing
core, in accordance with the principles of the present
disclosure;
[0033] FIG. 2 is a perspective view of a first portion of the
housing core shown in FIG. 1;
[0034] FIG. 3 is a perspective view of a second portion of the
housing core shown in FIG. 1;
[0035] FIG. 3A is a side elevation view of the housing core shown
in FIG. 1;
[0036] FIG. 3B is a cutaway view of the housing core shown in FIG.
3A;
[0037] FIG. 3C is a cutaway view of the housing core at the center
shown in FIG. 3B;
[0038] FIG. 3D is a cross-section view of the housing core shown in
FIG. 3C;
[0039] FIG. 4 is a top cutaway view of the housing core shown in
FIG. 1;
[0040] FIG. 4A is a side cross section view of the housing core
shown in FIG. 4;
[0041] FIG. 5 is a top plan view of the roof of a dwelling
constructed from housing core shown in FIG. 1;
[0042] FIG. 6 is a top plan cutaway view of a dwelling constructed
from the containerized housing core shown in FIG. 1; and
[0043] FIG. 7 is a top plan cutaway view of the housing core shown
in FIG. 6.
[0044] Like reference numerals indicate similar parts throughout
the figures.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The exemplary embodiments of the single, self-contained
housing core configured for containerization and related methods of
construction for dwellings and systems for intermodal freight
transport thereof are disclosed and discussed in terms of
prefabricated housing and more particularly, in terms of low cost,
sustainable dwellings and domiciles of shelter and safety. It is
envisioned that the advantages of the present disclosure may be
utilized for the benefit of those in need of a home and in various
geographies. The housing core and transport system may be employed
for domestic, regional and/or worldwide distribution. It is
envisioned that the present disclosure may be used with a range of
applications including those employing renewable energy and
conservation techniques. It is further envisioned that the housing
core is constructed to form a dwelling, which is designed to
provide a shelter in a package that can be deployed by those at
various skill levels including the most basic such as the end user.
The housing core may also include components addressing needs such
as personal cleanliness, food storage and preparation, and
education, and may include water supply, power supply, internet and
sanitation. The housing core can be factory built including
mechanical and electrical systems, and coupled with the local
construction of the shell or exterior walls of the dwelling unit to
create a complete dwelling unit.
[0046] It is also envisioned that the housing core may provide the
foundation for a single dwelling unit, combined with other housing
core(s) as a plurality of dwelling units and constructed together
as a multiple dwelling unit and/or constructed as a plurality of
units or plurality of multiple dwelling units to form a community
configuration. It is further envisioned that the housing core of
the present disclosure may alternatively be used with existing or
constructed on site utilities such as appropriate water, sewer and
power supply as provided by a local or regional utility and
connected as is known to one skilled in the art.
[0047] The following discussion includes a description of a housing
core, related components, assembly of the containerized unit,
containerized transport of the housing core, and exemplary methods
of constructing dwellings including the housing core in accordance
with the principles of the present disclosure. Alternate
embodiments are also disclosed. Reference will now be made in
detail to the exemplary embodiments of the present disclosure,
which are illustrated in the accompanying figures. Turning now to
FIG. 1, there is illustrated a single, self-contained housing core
10 configured for containerization in accordance with the
principles of the present disclosure.
[0048] The components of the housing core are fabricated from
materials suitable for prefabricated housing, such as, for example,
wood, compressed particle board, metals, plastics and/or other
materials, depending on the particular application and/or
preference of the manufacturer and/or end user. Semi-rigid and
rigid plastics as well as foam plastics are contemplated for
fabrication, as well as resilient materials, such as rubber. The
frame, walls, plumbing, circuitry, and interior fixtures of the
housing core may be fabricated from those suitable for a dwelling
and/or shelter application. One skilled in the art, however, will
realize that other materials and fabrication methods suitable for
assembly and manufacture, in accordance with the present
disclosure, also would be appropriate.
[0049] Detailed embodiments for the present disclosure are
disclosed therein, however, it is to be understood that the
described embodiments are merely exemplary of the disclosure, which
may be embodied in various forms. Therefore, specific functional
details disclosed herein are not to be interpreted as limiting, but
merely as a basis for the claims and as a representative basis for
teaching one skilled in the art to variously employ the present
disclosure in virtually any approximately detailed embodiment.
[0050] Referring to FIGS. 1-3, housing core 10 is configured for
transport as a 20 foot intermodal container, which is handled and
stacked as a standard container pursuant to applicable ISO
standards, which are known to those skilled in the art. At the
desired location or final building site, the entire container and
components of housing core 10 will be used for construction of the
dwelling unit. For example, housing core 10 is transported in
containerized form having approximate dimensions,
20'.times.8'.times.9'6''. It is envisioned that other sized
container dimensions, such as 40 ft, 45 ft, 48 ft and 53 ft may be
employed including custom configurations.
[0051] Housing core 10 includes panels 12 used to protect housing
core 10 and its components. Panels 12 are configured as an outer
cover or protective skin for housing core 10. Panels 12 are removed
at the final building site and reused for construction. For
example, panels 12 may be reused to construct roof 86 (FIG. 5) of
the dwelling unit for housing core 10. Panels 12 may be used to
construct other portions of the dwelling unit. Panels 12 are
rectangular in configuration, however, other shapes are also
envisioned such as, circular, triangle, etc.
[0052] Panels 12 include access cavities 16, which communicate in
between cavity or cavities 14, discussed in more detail below, of
housing core 10. Cavities 16 are configured for receipt of the
forks of a forklift (not shown) or the like. As such, housing core
10 can be easily maneuvered and manipulated for shipping and
storage. It is envisioned that housing core 10 may not include
cavities 16 or include a single cavity 16, or multiple cavities
16.
[0053] Housing core 10 includes an injection molded first section,
such as, for example, a lower half 18, as shown in FIG. 2,
including a floor 20 and a first portion, such as, for example,
lower portion 22 of walls 24. It is contemplated that lower half 18
may be formed, alternative to injection molding, by various
fabrication methods such as manual construction, machine forming,
vacuum forming, etc. Floor 20 may include a platform, poured
foundation, etc.
[0054] Lower half 18 includes a first bathroom 26 with a shower 28,
a toilet 30 and sinks 32. Lower half 18 also includes a second
bathroom 34 with similar components, and a food preparation area 36
with sinks, countertop, etc. It is envisioned that lower half 18
may have various component configurations, such as a single bath,
alternate counter design, closets, showers or bathtub arrangement
and alternate access openings, and separate toilet rooms.
[0055] Housing core 10 includes an injection molded second section,
such as, for example, an upper half 38, as shown in FIG. 3. Upper
half 38 is joined with lower half 18 to define a plurality of
cavities 14. These cavities 14 define space to accommodate disposal
of various items, discussed below, as well as rooms, cabinets,
fixtures, appliances, etc. of the dwelling unit including housing
core 10.
[0056] Upper half 38 includes a ceiling 40 and a second portion,
such as, for example an upper portion 42 of walls 24 separating the
core into two halves. Upper half 38 includes a reservoir, such as,
for example, a water tank 44. It is contemplated that upper half 38
may be formed, alternative to injection molding, by various
fabrication methods such as manual construction, machine forming,
vacuum forming, etc. It is further contemplated that housing core
10 may be formed as a single structure such that the first section
and the second section are connected and subsequent joining of the
halves is not required. The first section and the second section
may be monolithically formed, integrally connected, etc. It is
envisioned that the reservoir may be configured to support other
fluids in multiple compartments and/or other materials.
[0057] Referring to FIGS. 3A, 3B, 3C and 3D, the arrangement of
cavities disposed with housing core 10, walls 24 and floor 20 are
designed to achieve the maximum strength for each molded half 18,
38. Both upper half 38 and water tank 44 of upper half 38 are
reinforced by vertical ribs disposed along housing core 10 in both
directions. Housing core 10 includes walls 102 (FIGS. 2 and 7) of
the toilet and bath enclosure as well as a longitudinal rib 106
disposed adjacent food preparation area 36. When halves 18, 38 are
joined, the resultant section is an I-beam configuration with web
106 such that reinforcing ribs support the top 40 and bottom
flanges 20. The connection between upper half 38 and lower half 18
is proximate to the neutral axis of the structure of housing core
10 and be staggered or offset where the stresses are minimal. Walls
102 create additional reinforcing such as by creating box beam
cross sections.
[0058] The ends of housing core 10 are solid (FIG. 3A) as is the
center cross section (FIG. 3C) and corners 51, which can be further
reinforced, to accommodate the handling and lifting stresses
applied to housing core 10 during movement and handling. These
stresses distribute through I-beam configuration (106+20+40) (FIG.
3D) of the structure of housing core 10, as well as exterior panel
12 cladding, which is in place when lifting occurs. I-beam
configuration (106+20+40) also provides support for internal
connections, walking surfaces and attachment points of housing core
10 for reinforcement for day-to-day loads applied to housing core
10 and its components. This configuration also creates lateral
stability, which facilitates construction of the completed
dwelling. Reinforcement can be incorporated into housing core 10 to
accommodate stresses in an efficient manner.
[0059] Referring to FIGS. 4, 4A and 5, beams 78 are used for the
structural framing of roof 86. These beams 78 are placed below
ceiling 40 and run the length and the width of housing core 10
through aligned openings 58. Access through ports 16 allow a
forklift type machine to lift housing core 10 utilizing the
strength and placement of beams 78 to position it into its final
prepared site.
[0060] Upper half 38 stores a roofing membrane 46 to be deployed
out on the deck of roof 86. Upper half 38 includes intermodal
corner fittings 50 and photovoltaic panels 90, which is installed
with the containerized housing core 10 prior to transport. A
natural light and ventilation shaft 54 may be disposed with ceiling
40. Upper half 38 also includes openings 56, which facilitate
alignment of portions 22 and 42 of walls 24. Openings 58 of upper
half 38 facilitate loading and unloading of beams 78 for roof 86.
It is envisioned that upper half 38 may have various component
configurations, such as alternate opening disposal, and provide
storage for various items. Roof 86 may be constructed from various
materials.
[0061] Deployment items and installed components, as will be
discussed in further detail below, are disposed with lower half 18
and upper half 38. Implants are disposed within lower half 18 and
upper half 38 and are included in the molding process. Implants
include high pressure laminate floor surfaces, plumbing pipe trees,
electrical wire harness, and receiver fittings, etc. Incidental or
loose items are also disposed with lower half 18 and upper half 38,
in spaces such as 14, 67, 67a, 44 and 82.
[0062] Housing core 10 is a system, which facilitates transport and
storage of its components. The components are used for the
construction of the corresponding dwelling unit including housing
core 10. It is contemplated that components may also be disposed in
shower stalls 67, 67a of baths 26 and 34, respectively. In its
containerized form in preparation for transport, housing core 10
has first bathroom 26 and second bathroom 34, which define suitable
bathing and toilet spaces for use. Each bathroom 26, 34 may have
natural light and ventilation, as shown in FIG. 3. Each bathroom
26, 34 may be variously configured and dimensioned with housing
core 10. For example, each bath may be approximately 50 square feet
in floor space. It is envisioned that food preparation area 36 has
a 13 foot long counter with cabinets and appliances. Water tank 44
and photovoltaic solar array 90 may be built in with ceiling 40.
Water and electric systems along with their fixtures are disposed
within housing core 10 and are installed prior to transport. It is
envisioned that water tank 44 is a primary water reservoir,
however, housing core 10 may include a secondary reservoir, or a
plurality of reservoirs.
[0063] In containerized form in preparation for transport, housing
core 10 includes exterior windows and doors 72 disposed within the
space and area of cavities 14 defined by first bathroom 26. It is
envisioned that 8-10 windows/doors may be disposed therein.
[0064] A septic tank 74 is disposed within the space and area of
cavities 14 defined by second bathroom 34. It is envisioned that
septic tank 74 is approximately 900 gallons although other sizes
are contemplated. A back up battery 52 is stored within housing
core 10.
[0065] Aligned openings 58 provide access for placement and
transport of beams 78. For example, multiple beams 78, which are
fill length, for example, 19'6'' long, can be stored over or
through shower stall 67 and 67a and extend the length of housing
core 10. Beams 78 can be accessed for loading and unloading through
aligned openings 58. Beams 78 may be stored at an area just below
the ceiling of first bathroom 26 and through second bathroom 34
with access through aligned openings 58 and above windows 72 and
tank 74. Branches 64 extend electric and waste water hook-up to
septic tank 74, and electric to spaces 100, are also included with
core 10.
[0066] The advantageous design of the present disclosure does not
require installers skilled in the art of electrical or plumbing. If
the final site is in a region where heating is required, this can
be provided through a separate heating system of housing core 10
such as thermal solar or conventional boilers, which can be
included as a loose item. Such loose items can vary in style
depending on climate.
[0067] In another embodiment, a method for intermodal freight
transport of the containerized housing core 10 is provided. This
method includes the steps of providing housing core 10, which
includes lower half 18 and upper half 38. The molded shell or lower
and upper halves 18, 28 of housing core 10 enclose and support the
integrated systems for the dwelling structure employing housing
core 10, which are installed prior to transport.
[0068] The shell of housing core 10 also serves as a structural
carrier for other separate and loose components as discussed
herein. Lower half 18 and upper half 38 are injection molded as is
known to one skilled in the art in a configuration to conform to
standard intermodal container dimensions. It is contemplated that
housing core 10 may be formed as a single structure. Various
components, as discussed herein, are implanted with lower half 18
and upper half 38 during formation of housing core 10.
[0069] The lower and upper halves 18, 38 are injection molded
utilizing a high, (for example, 3 to 6 pound per cubic foot)
density foam plastic (for example, Styrofoam) material, which is
injected and cured in the mould as is known to one skilled in the
art. A wood matrix material and/or recycled waste material may also
be used for fabrication of halves 18, 38. The molds may be made of
steel or aluminum and configured to fabricate lower half 18 and
upper half 38. This advantageous configuration allows the draft
needed for releasing the halves 18, 38 from the moulds.
[0070] Further, this process allows implants to be placed into the
mould before injection of the plastic or other material. Such
implants could be high pressure laminate floor surfaces, plumbing
pipe trees and receiver fittings, electric chases or harnesses,
reinforcing grounds or attachment points, shower pans 28, and
universal intermodal corner fittings 50 and reinforced edges 51.
Implants can include waste lines cast into mould of housing core 10
and have a terminus at either end to be connected to the exterior
installed septic tank 74, as shown in FIG. 6.
[0071] After each of first half 18 and second half 38 have been
released from their respective moulds, a process to join the
sections and finish the connections and surfaces is employed. It is
envisioned that a coating may be applied to the various surfaces
such as a hard finishing compound, etc. Housing core 10 is joined
with corner reinforcement 51 and other reinforcements, and conforms
to international intermodal container standards. Lower half 18 and
upper half 38 are joined, which creates a plurality of cavities 14
therebetween. Cavities 14 are disposed within housing core 10 about
the various structures of housing core 10, such as bathrooms,
walls, partitions, etc. Various components are installed with lower
half 18 and upper half 38.
[0072] Installed components such as refrigeration 62, toilets 30,
sinks 32, solar panels 90 and battery bank 52 are then added to
housing core 10. Installed components may be used with housing core
10 to achieve the overall goals of enhanced energy efficiency and
conservation, long term reliability and simplicity in use.
Installed components are completely installed into housing core 10
and connectable with core or local utilities. No additional or
minimal work is required at the final building site for installed
components. It is contemplated, however, that parts of systems may
be added or created during factory molding of housing core 10 such
as shower pans 28, skylights 54, cabinets and countertops. Such
additional systems may include water conserving techniques and
recycling, and related equipment, including bathing, laundering and
sanitary components. Purification systems may also be employed.
[0073] Housing core 10 may also include a highly efficient
photovoltaic system with battery storage and computer power
management to include lighting, internet and ventilation. These
systems can be installed with ceiling 40 adjacent and under the rim
of water tank 44. Batteries 52 are disposed below ceiling 40 in the
central part of housing core 10. Other placement configurations are
also envisioned.
[0074] The systems of housing core 10 may also include energy
efficient food management equipment, and cooking and cleaning
systems. These may include highly efficient refrigeration, which
would warm water held in a separate pre-molded roof tank. Cooking
equipment can be equipped with anti-bacterial devices such as
ultraviolet light exposure devices.
[0075] Roofing membrane 46 is preinstalled or flashed into the
inner wall of water tank 44 and easily deployed by rolling it out
and unfolding it onto roof deck 86. It is contemplated that a
roofing membrane is provided for each side of roof 86. It is
further contemplated that tank 44 may be configured to collect
and/or harvest natural elements, such as, for example, rain, water
condensation, and may include solar collecting elements.
[0076] Deployment items or materials needed for the completion of
the housing unit are disposed within the plurality of cavities 14.
Deployment items include beams 78, or the structural components to
span from the edge of the housing core 10 at the final site to the
locally built exterior walls 88. For example, beams 78 are
fabricated from composite materials and sized to span the 19'-6''
long length of sleeping rooms 100 and common room 98, and are
sloped to collect rainwater and drain into water reservoir 44.
Beams 78 create roof 86. Panels 12 span roof 86 creating a solid
deck surface onto which roofing membrane 46 is deployed. It is
contemplated that panels 12 may be about 1 inch thick and 4' by 8'
in size, and that a plurality of panels 12 may be used, such as,
for example, seventy. Windows 72 and doors with screens are
fabricated, for example, with PVC material and glass. Windows 72
and doors are installed into walls 88, which are constructed from
local materials.
[0077] A sanitary system of housing core 10 includes septic tank
74, which (for example, 800 gallons and/or 5' by 5' by 4'
fabricated from polypropylene) is installed into the final site
adjacent to the constructed housing core 10 (FIG. 6). Tank 74 is
pre plumbed with a leaching field and attached to branch
connections 64 of the waste line of housing core 10. This sanitary
system includes a combination of waterless composting and
conventional septic as is known to one skilled in the art. It is
envisioned that advanced concepts in sanitary design may be used
which are designed to generate organic soil from human waste as is
known to one skilled in the art. An additional water storage tank
in the form of a flexible fabric tank can be disposed at the final
site, above or below ground. The additional tank may hold an
additional 1,000 gallons of water. Depending on the climate, one or
several additional tanks can be employed to supplement the 1,000
gallon water tank 44 of housing core 10.
[0078] When the moldings are completed and the installed components
are tested (for example, by connection to utility systems and
quality tests), the remaining cavities 14 within housing core 10 is
filled with deployment items such as beams 78, which slide in
through openings 58 at each end of housing core 10, and are placed
under ceiling 40 running the full length of housing core 10. Septic
tank 74 is disposed in second bathroom 26. Doors and windows 72 are
disposed on their edge on the floor in first bathroom 34. Secondary
water tanks are folded and positioned above the toilets. Panels 12
sheath the entire housing core 10, including four sides and roof
86. It is envisioned that panels 12 may be three to four deep with
staggered joints, which may be screwed into structural implants as
a final step to reinforce and protect the entire package of
components of housing core 10.
[0079] Deployment items are disposed within the plurality of
cavities 14 of housing core 10. It is envisioned that such various
efficient building products may be utilized to construct the
dwelling unit employing housing core 10. It is contemplated that
these items are partially installed into the core itself, such as
roofing membrane, or are provided loose ready for installation at
the final site.
[0080] Incidental or loose items can include cooking utensils,
tools, Portland cement (for example, to stabilize compacted floor
and foundation construction), polypropylene carpet, moderate
heating system and internet ready computers. Such incidental items
may also include bicycles, clothing, temporary supply of food,
bedding, books, school supplies, musical instruments, sporting
goods, etc.
[0081] Incidental items can be placed in the remaining spaces,
including the shower stalls, areas in and above the cabinets and
counters, space in water tank 44 and below the solar panels. It is
envisioned that these spaces total approximately 300 cubic feet and
are concealed and protected under panels 12 sheathing.
[0082] Housing core 10 is transported in containerized form via
intermodal freight transport as is known to one skilled in the art.
Referring to FIGS. 5-7, the containerized housing core 10 is
transported via intermodal transport to the final site or desired
location for constructing the dwelling unit. Housing core 10 is
disposed for construction at the final site.
[0083] Deployment items and incidental items, are removed from
housing core 10 for assembly and/or construction. Branches 64,
which extend the electric and sanitary systems beyond the core as
needed to construct the dwelling unit are assembled and connected
as required. Roof 86 is constructed, as shown in FIG. 5, from beams
78 spanning between the upper edge of housing core 10 and final
site exterior extension walls 88. Interior portion wall 89 could be
built in various configurations, in accordance with the principles
of the present disclosure. Photovoltaic cells 90 are fixed and
flank each side of light/vent shaftway 54. Beams 78 and panels 12
are configured to form a rainwater collection surface 92. An
interface 94 defines a conduit between collection surface 92 and
water tank 44. Membrane 46 is rolled out to cover the roof deck
created by panels 12. It is contemplated that membrane 46 may cover
all or only a portion of the roof deck.
[0084] Extension walls 88 are constructed with housing core 10 to
form a 1,200 square foot dwelling. Other sized dwelling space is
also contemplated. The dwelling space may be variously configured
to meet the requirements of a particular building site and/or
preferences of a user. As shown in FIG. 6, the dwelling unit
includes a porch 96. Porch 96 may be variously configured and
dimensioned, or may not be included. The remaining portion of
housing core 10 is centrally disposed within the dwelling unit
adjacent to living area 98 and sleeping areas 100. The toilets are
connected for communication with septic tank 74, which is buried
exterior and adjacent to the dwelling unit. First bathroom 26 and
second bathroom 34 are desirably located, as well as food
preparation area 36. Windows 72 and doors are mounted and
positioned with extension walls 88 as desired.
[0085] In an alternate embodiment, housing core 10 includes the
materials for extension walls, similar to extension walls 88, which
are assembled with housing core 10, via disposal with cavities 14,
prior to transport at a manufacturing facility or the like. Housing
core 10 includes the materials of the extension walls to form a
complete dwelling or housing unit for inter modal freight transport
and construction at a final building site, similar to that
described herein, to provide a home in various geographies. Housing
core 10 has the materials to create an exterior wall system
including the extension walls to complete the dwelling unit
including housing core 10. These materials may include a plurality
of columns 79 (vertical structural components), some additional
beams and about 2,000 square feet of reinforced fabric, which would
be stretched between the columns and extend from roof 86 to the
perimeter base of exterior walls (88). Other materials and
quantities are also contemplated.
[0086] It will be understood that various modifications may be made
to the embodiments disclosed herein. Therefore, the above
description should not be construed as limiting, but merely as
exemplification of the various embodiments. Those skilled in the
art will envision other modifications within the scope and spirit
of the claims appended hereto.
* * * * *