U.S. patent application number 12/567341 was filed with the patent office on 2010-09-16 for net-zero energy mechanical core and method.
Invention is credited to William Malpas.
Application Number | 20100229472 12/567341 |
Document ID | / |
Family ID | 42729538 |
Filed Date | 2010-09-16 |
United States Patent
Application |
20100229472 |
Kind Code |
A1 |
Malpas; William |
September 16, 2010 |
NET-ZERO ENERGY MECHANICAL CORE AND METHOD
Abstract
A pre-fabricated service module suitable for use in a
multi-story building, includes (a) a chassis dimensioned to be
stacked with another pre-fabricated service module to match the
floors of the multi-story building; (b) a waste and ventilation
subassembly providing access to bathroom and kitchen waste rough-in
plumbing and ventilation; (c) a water and electrical subassembly
providing access to water and electrical supplies; and (d) a ducts
and fan subassembly providing access to a heating and air
circulation system.
Inventors: |
Malpas; William; (Berkeley,
CA) |
Correspondence
Address: |
HAYNES AND BOONE, LLP;IP Section
2323 Victory Avenue, Suite 700
Dallas
TX
75219
US
|
Family ID: |
42729538 |
Appl. No.: |
12/567341 |
Filed: |
September 25, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61100648 |
Sep 26, 2008 |
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Current U.S.
Class: |
52/79.1 ;
52/173.3; 52/220.2; 52/745.1 |
Current CPC
Class: |
E04C 2/521 20130101;
E04F 17/08 20130101 |
Class at
Publication: |
52/79.1 ;
52/220.2; 52/173.3; 52/745.1 |
International
Class: |
E04C 2/52 20060101
E04C002/52; E04B 2/56 20060101 E04B002/56 |
Claims
1. A pre-fabricated service module suitable for use in a
multi-story building, comprising: a chassis dimensioned to be
stacked with another pre-fabricated service module to match the
floors of the multi-story building; a waste and ventilation
subassembly providing access to bathroom and kitchen waste rough-in
plumbing and ventilation; a water and electrical subassembly
providing access to water and electrical supplies, the water and
electrical subassembly including electrical connections customized
for a thermal control system for at least a portion of the
multi-story building, including electrical connections to a
controller, sensors and thermal actuators; and a ducts and fan
subassembly providing access to a heating and air circulation
system.
2. A pre-fabricated service module as in claim 1, further
comprising recesses for medicine cabinets.
3. A pre-fabricated service module as in claim 1, further
comprising a backing sufficiently strong for accessible or
adaptable grab bars.
4. A pre-fabricated service module as in claim 1, wherein the
chassis is-precision cut to a predetermined tolerance.
5. A pre-fabricated service module as in claim 1, wherein piping in
the waste and ventilation subassembly comprises cast iron.
6. A pre-fabricated service module as in claim 1, wherein piping in
the water and electrical subassembly comprises copper.
7. A pre-fabricated service module as in claim 1, further
comprising sound isolation pads for sound isolation in piping of
the subassemblies.
8. A pre-fabricated service module as in claim 1, wherein the
chassis includes shaft wall studs and shaft wall liners.
9. A pre-fabricated service module as in claim 1, wherein the waste
and ventilation module comprises two or more components selected
from the group consisting of tub and shower rough-in plumbing,
floor-mounted toilet rough-in plumbing, lavatory rough-in plumbing,
kitchen sink rough-in plumbing, waste and ventilation risers, and
sound isolation for waste and ventilation piping.
10. A pre-fabricated service module as in claim 1, wherein the
water and electrical subassembly comprises two or more components
selected from the group consisting of hot water supply and hot
water circulation risers, cold water riser, hot and cold water
fixture supplies, and sound isolation for the water piping.
11. A pre-fabricated service module as in claim 1, wherein the
water and electrical subassembly comprises two or more components
selected from the group consisting of pre-wired plugs, switches and
light fixture boxes, and conduit and conductors a the Photo Voltaic
system.
12. A pre-fabricated service module as in claim 1, wherein the
ducts and fan subassembly comprises two or more components selected
from the group consisting of ducts for the air circulation system,
kitchen range hood exhaust duct, bath exhaust fans and ducts, bath
fan chase riser, fire and sound caulking at duct penetrations, and
dryer vent.
13. A pre-fabricated service module as in claim 1, wherein the
ducts and fan subassembly includes fittings which are pretested to
a pre-defined specification in the pre-fabricated service module
prior to shipping to a job site.
14. A pre-fabricated service module as in claim 1, wherein hot
water taps in that portion of the multi-story building are located
at predetermined positions, and wherein a hot water supply is
connected to the water and electrical subassembly such that a total
distance from the hot water supply to the hot water taps are less
than a specification value.
15. A method for providing access to essential services in a
multi-story building, comprising: providing a chassis dimensioned
to be stacked with another pre-fabricated service module to match
the floors of the multi-story building to form a pre-fabricated
service module; including in the pre-fabricated service module a
waste and ventilation subassembly providing access to bathroom and
kitchen waste rough-in plumbing and ventilation; including in the
pre-fabricated service module a water and electrical subassembly
providing access to water and electrical supplies, the water and
electrical subassembly including electrical connections customized
for a thermal control system for at least a portion of the
multi-story building, including electrical connections to a
controller, sensors and thermal actuators; including in the
pre-fabricated service module a ducts and fan subassembly providing
access to a heating and air circulation system; installing the
pre-fabricated service module in a selected floor of the building;
and connecting fixtures on the selected floor to respective one of
the waste and ventilation subassembly, water and electrical
subassembly and ducts and fan subassembly.
16. A method as in claim 15, wherein the waste and ventilation
module comprises two or more components selected from the group
consisting of tub and shower rough-in plumbing, floor-mounted
toilet rough-in plumbing, lavatory rough-in plumbing, kitchen sink
rough-in plumbing, waste and ventilation risers, and sound
isolation for waste and ventilation piping.
17. A method as in claim 15, wherein the water and electrical
subassembly comprises two or more components selected from the
group consisting of hot water supply and hot water circulation
risers, cold water riser, hot and cold water fixture supplies, and
sound isolation for the water piping.
18. A method as in claim 15, wherein the water and electrical
subassembly comprises two or more components selected from the
group consisting of pre-wired plugs, switches and light fixture
boxes, and conduit and conductors a the Photo Voltaic system.
19. A method as in claim 15, wherein the ducts and fan subassembly
comprises two or more components selected from the group consisting
of ducts for the air circulation system, kitchen range hood exhaust
duct, bath exhaust fans and ducts, bath fan chase riser, fire and
sound caulking at duct penetrations, and dryer vent.
20. A method as in claim 15, further comprising pre-testing, in the
pre-fabricated service module, fittings in the ducts and fan
subassembly to a pre-defined specification prior to shipping to a
job site.
21. A method as in claim 15, wherein hot water taps in that portion
of the multi-story building are located at predetermined positions,
and wherein a hot water supply is connected to the water and
electrical subassembly such that a total distance from the hot
water supply to the hot water taps are less than a specification
value.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to and claims priority of
U.S. Provisional Patent Application Ser. No. 61/100,648, entitled
"Mechanical and Electrical Core and Method," by W. Malpas, filed on
Sep. 26, 2008, which is hereby incorporated by reference in its
entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to modular housing unit
design. In particular, the present invention relates to the design
of a modular component that provides functional units (e.g.,
kitchens and bathrooms) access to essential services (e.g.,
electrical, gas, water and ventilation systems).
[0004] 2. Discussion of the Related Art
[0005] Existing pre-fabricated service modules are each a
pre-assembled collection of the basic components of a dwelling unit
which provide accesses to water and waste (sanitation) systems
exist. Such a module comes pre-tested, and provides standard
hook-ups to the services at predetermined positions, so that the
module is substantially ready for connection when delivered to the
building site. Such pre-fabricated service modules enjoy the
benefits of mass production (i.e., low cost and relatively high,
reproducible quality) relative to conventional construction
methods, where accesses to the services are built at the building
site and more or less custom-designed for each building unit, No
pre-fabricated module is believed to exist which also provide
access to electrical and heating, ventilation and air conditioning
(HVAC) services, in addition and water and waste services, or which
is designed for multi-story constructions.
SUMMARY
[0006] A pre-fabricated service module suitable for use in a
multi-story building, includes (a) a chassis dimensioned to be
stacked with another pre-fabricated service module to match the
floors of the multi-story building; (b) a waste and ventilation
subassembly providing access to bathroom and kitchen waste rough-in
plumbing and ventilation; (c) a water and electrical subassembly
providing access to water and electrical supplies; and (d) a ducts
and fan subassembly providing access to a heating and air
circulation system.
[0007] A pre-fabricated service module according to the present
invention organizes plumbing, electrical, and HVAC trades and
services in one compact, efficient area, and is designed for easy
assembly to reduce costs. The pre-fabricated module approach
obviates the need to cut, and avoids competition by different
trades over valuable wall space. The chassis containing the service
subassemblies are precisely cut, so as to allow stacking for
multi-story installation. Extensive use of sound absorption
materials and design minimize sound transmission from unit to unit
in a multi-unit building.
[0008] The present invention is better understood upon
consideration of the detailed description below, in conjunction
with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an axonometric view of pre-fabricated service
module 100, in accordance with one embodiment of the present
invention.
[0010] FIG. 2 shows chassis 1 without the installations of the
services.
[0011] FIG. 3 shows the waste and ventilation subassembly 300 that
is incorporated into pre-fabricated service module 100 of FIG.
1.
[0012] FIG. 4 illustrates water and electrical subassembly 400 that
is incorporated into pre-fabricated service module 100 of FIG.
1.
[0013] FIG. 5 illustrates ducts and fans subassembly 500 that is
incorporated into pre-fabricated service module 100 of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] According to one embodiment, a pre-fabricated module
providing access to water, waste (sanitation), electrical and HVAC
systems of a housing is provided. In this embodiment, most of the
mechanical and electrical components are contained in a simple,
clean assembly, which is assembled in a off-site manufacturing
facility and brought to the building site for installation.
[0015] FIG. 1 is an axonometric view of pre-fabricated service
module 100, in accordance with one embodiment of the present
invention. As shown in FIG. 1, pre-fabricated service module
includes (a) chassis 1, which is cut by precision computer
numerically controlled (CNC) machinery; (b) backing 2 to allow
installation of handicapped accessible or adaptable grab bars, (c)
tub and shower mixer rough-in 3, (d) floor-mounted toilet rough-in
4, (e) lavatory rough-in 5, (f) kitchen sink rough-in 6 (not
shown), (g) waste and ventilation risers 7, (h) sound isolation for
waste and ventilation piping 8 (not shown), (i) hot water supply
and hot water circulation risers 9, (j) cold water riser 10, (k)
hot and cold water fixture supplies 11, (l) washing machine box 12,
(m) sound isolation for the water piping 13 (not shown), (n)
pre-wired plugs, switches and light fixture boxes 14, (o) sound
isolation pads for the electrical boxes 15 (not shown), (p) conduit
and conductors for the Photo Voltaic (i.e., solar energy
collection) system 16, (q) ducts for the air circulation system 17,
(r) kitchen range hood exhaust duct 18, (s) recesses for medicine
cabinets 19, (t) bath exhaust fans and ducts 20, (u) bath fan chase
riser 21, (v) fire and sound caulking at duct penetrations 22 (not
shown), and (23) dryer vent 23.
[0016] In one embodiment, cast iron piping is used in waste and
ventilation piping and copper piping for water. The piping is
isolated from Chassis 1 by isolation pads. Similarly, electrical
boxes are wrapped in sound absorption pads. The mass of the shaft
wall system further deadens any sound transmission from within the
shaft and from unit to unit through the shaft. Low Sone bath fans
are used with 26 gauge ducting to minimize the noise of air
movement.
[0017] As seen from FIG. 1, the pre-fabricated service module of
the present invention provides a full set of bathroom and kitchen
fixture rough-ins plumbing, in addition to ducts for the air
circulation system and exhaust fans, conduit and conductors for a
photovoltaic system, and pre-wired plugs, switches and light
fixture boxes for the electrical system. In one embodiment, access
panels for maintenance are also provided.
[0018] Various configurations of mechanical and electrical
subassemblies (i.e., subassemblies with variations in the selection
or placements of components for each service) are available to
accommodate different project requirements and designs. The
connections from module to module, particularly between stacked
upper and lower service modules, are facilitated by the careful
design of the chassis dimensions and the precise manufacturing and
locations of the chassis and included services.
[0019] FIG. 2 shows chassis 1, without the installations of the
services. Chassis 1 may be provided by Type I (i.e.,
non-combustible) metal chassis, with metal shaft wall studs and
shaft wall liner. Alternatively, Chassis 1 may also be provided by
Type V (non-rated) or Type V (one-hour), wood chassis, with wood
studs, metal tracks. Also shown in FIG. 1 are penetrations 1A in
chassis top and bottom plates, which precisely locate services in
the "X-Y" axis, and penetrations 1B in the horizontal gussets
precisely locate services in the "Z" axis, and backing 2 for
handicapped grab bar sand accessories
[0020] FIG. 3 illustrates waste and ventilation subassembly 300
that is incorporated into pre-fabricated service module 100 of FIG.
1. As shown in FIG. 3, waste and ventilation subassembly 300
includes tub and shower rough-in 3, floor-mounted toilet rough-in
4, lavatory rough-in 5, kitchen sink rough-in 6 (not shown), waste
and ventilation risers 7, and sound isolation for waste and
ventilation piping (not shown).
[0021] FIG. 4 illustrates water and electrical subassembly 400 that
is incorporated into pre-fabricated service module 100 of FIG. 1.
Water and electrical subassembly 500 includes hot water supply and
hot water circulation risers 8, cold water riser 9, hot and cold
water fixture supplies 10, sound isolation for the water piping 12
(not shown), pre-wired plugs, switches and light fixture boxes 14,
and conduit and conductors for the Photo Voltaic system 16. As
shown in FIG. 4, the efficient plumbing design and assembly
minimize the distance required for hot water heating, thereby
reducing overall energy required for domestic hot water, which
typically accounts for up to 40% of home energy usage. In this
embodiment, electrical connections for a controller for the thermal
system of the floor on which pre-fabricated service module 100 is
to be installed, and its associated sensors and activators are
provided in water and electrical subassembly 400. These connections
provide effective energy control and monitoring.
[0022] FIG. 5 illustrates ducts and fans subassembly 500 that is
incorporated into pre-fabricated service module 100 of FIG. 1.
Ducts and fan subassembly 500 includes ducts for the air
circulation system 17, kitchen range hood exhaust duct 18, bath
exhaust fans and ducts 20, bath fan chase riser 21, fire and sound
caulking at duct penetrations 22, (not shown) and dryer vent 23.
Air ducts in air circulation system 17 are assembled in the factory
to meet high standards for low duct leakage and tight fittings,
which reduce any energy loss from potential failure points. The
assembly is pre-engineered and tested in the factory.
[0023] Therefore, multiple trades and services are organized in one
compact, efficient area. Pre-fabricated service module 100 is
designed to allow stacking in a building with multiple stories.
Additional services may be configured into such service module,
such as additional electrical, low-voltage, and rain water
leaders.
[0024] To install a pre-fabricated service module of the present
invention, precise, stacked openings are blocked-out in the floors,
or openings are left in the roof. The pre-fabricated service module
may be equipped with lifting rings for crane handling, skids for
forklift or pallet jack handling, and flanges to mount to the
floors. In a typical installation, the flanges are first unbolted
and the pre-fabricated service module is maneuvered to the correct
floor and properly aligned. The pre-fabricated service module is
then secured by bolting the flanges to the floor. Alternatively,
the flanges may be welded or fastened to the building frame. The
pre-fabricated service module can also be further secured by having
it in place before pouring of the floor, and cast into the
concrete. The pre-fabricated service module can also be bolted on
to plywood floor.
[0025] The above detailed description is provided to illustrate the
specific embodiments of the present invention and is not intended
to be limiting. Numerous variations and modifications within the
scope of the present invention are possible. The present invention
is set forth in the following claims.
* * * * *