U.S. patent application number 12/649287 was filed with the patent office on 2011-05-05 for complete prefabricated mechanical & utility system.
Invention is credited to Brett Alois Buchmann.
Application Number | 20110099918 12/649287 |
Document ID | / |
Family ID | 43923899 |
Filed Date | 2011-05-05 |
United States Patent
Application |
20110099918 |
Kind Code |
A1 |
Buchmann; Brett Alois |
May 5, 2011 |
COMPLETE PREFABRICATED MECHANICAL & UTILITY SYSTEM
Abstract
A complete prefabricated mechanical and utility unit for
residential or commercial use that includes all utilities and
mechanics for servicing the adjacent uses. Once attached to utility
supply lines the invention does not require work from skilled labor
to operate. The unit has the ability to support satellite services
as required.
Inventors: |
Buchmann; Brett Alois;
(Hermosa Beach, CA) |
Family ID: |
43923899 |
Appl. No.: |
12/649287 |
Filed: |
December 29, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61204087 |
Jan 2, 2009 |
|
|
|
Current U.S.
Class: |
52/79.1 |
Current CPC
Class: |
E04B 1/34869 20130101;
E03C 1/01 20130101 |
Class at
Publication: |
52/79.1 |
International
Class: |
E04H 14/00 20060101
E04H014/00 |
Claims
1. A complete prefabricated mechanical and utility unit in the use
of building construction comprising: (a) A structure with the
ability to house and distribute all incorporated systems. (b) All
building systems that will provide service the adjacent uses
2. Said building systems (1a) shall include multiple or all but not
limited to: electrical, gas, potable water, grey water, cold water,
hotwater, solid waste, grey waste, hvac, lighting, data, phone,
cable, dsl, satellite, solar water, photovoltaic, water
purification, automation, ventilation, and metering
3. The said unit is installed complete with the ability to provide
outside systems with services.
Description
FIELD OF INVENTION
[0001] The present invention relates to a prefabricated system
incorporating a complete mechanical and utility unit that can
operate as a stand alone "closed system" with the possibility of
elements being added on at the time of construction or at a later
date.
BACKGROUND
[0002] Traditional construction practices for constructing a
building are not efficient and wasteful of time of skilled labor,
materials and future resources to operate. One of the major
expenditures of the overall cost of any project is skilled labor
(e.g. Electricians, Plumbers, etc.). The skilled labor is also
required to work at the job site which is not efficient in many
ways. Two examples of this are: the skilled labor is required to
travel to and from the site and the skilled labor must relocate all
of their equipment throughout the project as the work is
completed.
[0003] The common solution to this problem has been to prefabricate
Modular buildings in part or whole. Current prefabrication
techniques can be classified in those two groups but both have
drawbacks. Whole fabricated buildings are difficult to transport to
the site and erect. Partially fabricated units are not complete and
must be assembled often resulting in double the amount of structure
(walls, slabs, etc.). Attaching said units also require a great
amount of on site skilled labor to assemble the mechanical systems.
The resultant joints between the units leave a potential for
failure. These prefabricated buildings or modules provide limited
design flexibility, allowing few configurations and not recognizing
specific site or design conditions.
[0004] In current building techniques incorporation of the
mechanical systems into the building can require unnecessary time,
for example the electrician may be required to come to the site
before the foundation pour to place electrical conduit. by limiting
the required integration of the mechanical system into the other
building materials it would greatly increase efficiency and reduce
costs.
[0005] Often storage space is limited and difficult to secure on a
construction site. Prefabrication offers a solution by not
requiring raw materials to be stored on site waiting to be
installed.
[0006] The idea of a grouping plumbing and mechanical walls
creating a service core is not a novel idea, but rather it is a
fundamental principle in the vertical organization of architecture.
One solution proposed by past inventions have created prefabricated
systems that can be stacked or assembled to create this service
core, but the connections and structural intersections make these
systems difficult to use in the field requiring special knowledge
for installation and construction. These connections are also a
possible point of failure in the systems.
[0007] Therefore devising building techniques that reduce skilled
labor and increase efficiency are desired.
SUMMARY OF THE INVENTION
[0008] I have discovered a novel construction system that would be
a complete prefabricated mechanical and utility unit, herein
referred to as "the unit". The system would include all mechanical
and utility systems for the building to operate. The Unit utilizes
the most efficient method of building (prefabrication) for the most
expensive part of construction (Mechanical & Utility
Systems).
[0009] The system is comprised of multiple walls and floor
diaphragms that provides structure while housing the mechanical
& utility systems.
[0010] These units could be assembled on an assembly line similar
to techniques used to manufacture automobiles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of the complete prefabricated
mechanical & utility system
[0012] FIG. 2 is a axonometric view of the unit, installed as
possible use
[0013] FIG. 3 is a perspective view of the unit, installed as
possible use
[0014] FIG. 4 is a perspective view of the unit, installed as
possible use
[0015] FIG. 5 is a perspective view of the unit, looking up a
ceiling cavity
[0016] FIG. 6 is a perspective view of the unit, installed as
possible use
[0017] FIG. 7 is a perspective view of the unit, installed as
possible use
[0018] FIG. 8 is a perspective view of the unit, installed as
possible use
[0019] FIG. 9 is a perspective view of the embedded mechanical
systems
[0020] FIG. 10 is a axonometric view of the foundation
[0021] FIG. 11 is a diagram of the possible delivery system
[0022] FIG. 12 is a longitudinal elevation of the unit
[0023] FIG. 13 is a section through the unit
[0024] FIG. 14 is the exterior elevation
[0025] FIG. 15 is the interior elevation
[0026] FIG. 16 is a plan view of the roof top
[0027] FIG. 17 is a plan view of the Foundation
[0028] FIG. 18 is a plan view of the unit
[0029] FIG. 19 is an example first floor plan using the unit
[0030] FIG. 20 is an example second floor plan using the unit
[0031] FIG. 21 is a plan view of an example hotel use
[0032] FIG. 22 is a plan view of possible configuration
[0033] FIG. 23 is a plan view of possible configuration
[0034] FIG. 24 is a plan view of possible configuration
[0035] FIG. 25 is a plan view of possible configuration
[0036] FIG. 26 is a plan view of possible configuration
DETAILED DESCRIPTION OF THE INVENTION
[0037] Embodiments of the invention can be used in the construction
of buildings to reduce cost, improve efficiency, reduce
construction time, and decrease a buildings operational costs. The
unit is prefabricated at a factory and is of a transportable size.
The unit is transported to a site that is prepared for the
installation of the unit. The unit would preferably be fabricated
in an assembly line method.
[0038] The prepared site would preferably have foundation and all
utility inlets in place. A premade form is used to cast the
foundation and with ensure proper placement of utility inlets while
reducing the cost and waste of additional formwork when pouring the
foundation.
[0039] The invention is a part or whole of the mechanical and
utility systems for a building. Once installed and inlets have been
attached the system is able to operate. Additional elements may be
added at the site so that the unit can be customized to any
situation. The ability to be customized makes the system extremely
flexible and able to adapt to any situation, increasing its design
flexibility.
[0040] The unit is built of traditional building materials so that
no special knowledge is required to install, modify, or repair.
Wood framing is shown in FIG. 1 but other materials may be used to
satisfy structural or other limitations.
[0041] An advantage of prefabricating the mechanical system is that
it can be inspected prior to installation. Problems can be
addressed prior to the units being installed saving delays at the
site. The units can also be tested in the factory prior to shipment
ensuring high standard of quality. The automation system is
pre-programmed at the factory reducing the site work of the
automation technician.
[0042] The units contain all the meters to monitor and control all
the services. External digital readouts can be placed anywhere on
the exterior of the building as required by the utility services.
The unit otherwise would be able to connect to the utility
companies to report usages though wireless or data lines. Two way
communication would be possible allowing the utility to communicate
and control parts of the system as known in the art.
[0043] STRUCTURE--The vertical structural members (1) shows the
frame of the unit to be of typical construction materials. The rim
joist (2) shows the edge beam parallel to the long wall, thus
creating a cavity between the edge beam and the longitudinal wall.
The edge beam is able to support adjacent floor members. The
structural sheathing (3) will allow the unit to remain rigid during
transportation and may provide lateral resistance in the completed
building. A pressure treated sill (4) or similar material that
would allow the unit to be placed directly on the concrete
foundation. Anchoring hardware (5) such as hold-downs that would
securely fasten the unit to the foundation.
[0044] WEATHERPROOFING--The roof top waterproofing pan (8) is a one
piece liner made of a durable impervious material such as plastic
that lines the rooftop parapet area to waterproof it, and is
connected to the scupper (9) that is incorporated into the Liner
allowing water to exit the rooftop mechanical area. An overflow
scupper (10) located at a higher elevation allows water to escape
if the main scupper becomes obstructed. All weatherproofing
connectors and flashing may be also manufactured to ensure quality
of construction.
[0045] WATER--The water supply is connected at the water meter (15)
which is monitored by the automation system. All of the water
supplied to the unit is filtered at the water treatment module
(16). The potable water is then either sent into the cold water
supply line (14) or sent to the tankless water heater (19). The hot
water line (13) is supplied by the tankless water heater (19). The
hot and cold water lines service all the fixtures in the unit and
have additional connections to service other fixtures.
[0046] WASTE LINES--The washer drain (6) is installed at a location
that is ready for immediate use and is connected to grey waste line
(11). An overflow pan (7) made out of metal or plastic prevents
water leakage incase the washer fails and is connected to the grey
waste line (11). The shower/tub drain (21) is placed in location
for immediate use and is connected to the grey water line (11). The
Solid waste line (12) is installed in the unit that connects the
Sewer lateral to the plumbing fixtures that can not produce grey
water easily such as the toilets drain (22), kitchen sink (23), and
dishwasher. The waste line vent (20) is connected to the grey waste
line (11) and the solid waste line (12) to vent them through the
parapet of the unit.
[0047] GAS LINES--All required inlets and outlets are installed for
all gas appliances. The gas line (24) is connected at the Gas meter
(25) which is controlled through the automation system. The gas
line connects the equipment on the roof top such as the water
heater (19), heat pump (26), and generator (34). The gas line is
also connected to the clothes dryer (50) and to the stove connector
line (54).
[0048] HVAC--The airconditioner/heatpump (26) is controlled by the
automation system. The intake/exhaust grill (28) is made to
resemble a traditional chimney cap. The thermostat (29) is
controlled by the automation system.
[0049] ELECTRICAL--The electrical supply is connected at the
electrical meter (30) which is controlled by the automation system.
Conduit (33) connects the meter (30) to the Electrical panel (31).
The use of conduit and the properties of its material could reduce
the amount of EMF (Electrical Magnetic Fields) exposure to the user
of the unit. The electrical panel (31) is connected to and
controlled by the automation system (32). The generator (34)
provides backup power if electrical service is interrupted.
Lighting (35) is preinstalled in the unit. Electrical conduit (33)
is located at the edge beam (2) that is connected to the electrical
panel (31). This allows additional electrical fixtures to be placed
outside the unit and the wires can be fed to the panel.
[0050] AUTOMATION SYSTEM--Automation Systems are known in the art
but are currently expensive to install. The systems abilities are
able to be expanded upon by incorporating it into a prefabricated
system. The Unit does not require the use of an automation system
but by using an automation system it eliminates the need for
certain elements. Such elements are light switches, rather than
skilled labor required to install the lights outside the unit, the
lighting fixtures just need to be plugged into the automation
system.
[0051] PRE-INSTALLED ELEMENTS--Elements are included in the system
that allow future systems to be installed, but any of these
additional items could be incorporated into the unit if desired.
Such elements are a power converter (37) pre-installed so that
photovoltaic panels can be mounted on the building and plugged into
the unit. A solar water heater junction box (39) is also installed
so that solar water heaters can be mounted on the building and
plugged into the unit. A grey water holding tank (17) would store
grey water to be used at the site where potable water is not
required. A hydronic pump (18) would provide required pressure to
transport grey water from element (17) to outlet. An air handler
(27) that can be placed at any location in the project works in
conjunction with the compressor/heatpump (26) so all heating and
cooling requirements can be met. Added photovoltaic panels (36) can
be connected "plugged in" to power converter (37). Solar water
heaters (38) connect to solar water heater junction box (39).
[0052] VENTING--Venting for all the equipment is installed in the
unit terminating at the vent cap (43). Using the said ventcap
reduces the amount of roof penetrations of the adjacent building
reducing the chance of waterproofing failure, reducing the time of
the roof installation and reduces the amount of trade coordination.
The laundry dryer duct (40) is connected to the vent cap (43) and
is ready for connection to the dryer. The Laundry make up air (56)
is provided so that make up air is not required by additional means
required for gas appliances. The Laundry make up air (56) may use
means to reduces air humidity such as pressurization to increase
the efficiency of said dryer. The bathroom duct and fan (41) is
installed, connected to the vent cap (43) and ready for use to meet
required codes for ventelation of the said bathroom. The hood duct
(44) is installed and connected to the vent cap (43) and is
operable when connected to the Hood (45). The tankless water heater
(19) is equipped a exhaust vent (46) and an intake air vent (47).
The refrigerator vent (48) is provided to either exhaust the heat
generated by the refrigerator coils or use the exhaust heat to
assisting the tankless water heater (19) or the air
conditioner/heatpump (26) and is controlled by the automation
system. The rooftop mechanical area may be equipped with
ventilation as required by specific mechanical units. All or any of
the ventilation ducts may be equipped with mechanical means of
improving efficiency (i.e. fans)
[0053] SHOWER/TUB DRYER--The shower/tub dryer (50) is a element
that provides force air from the room that it is located or outside
air that is used to dry said area reducing humidity limiting the
growth of mold and fungus. The shower/tub dryer is controlled by
the automation system and may turn on or off when required to
reduce moisture levels as required and is connected to the vent cap
(43) via shower/tub duct vent (49).
[0054] DETECTORS--Detectors and sensors are placed throughout the
unit to monitor for system or building failures. The gas detector
(60) is located near the appliances that use gas or along parts of
the unit that gas might accumulate. The water detector (57) are
located along the floor and in the under floor vault, installed to
monitor if sink/tub overflows, washer malfunctions or if a pipe in
the walls rupture. A water sensor is also located in the roof
equipment area to warn if the scuppers are blocked and the roof pan
is filling with water. Fire detectors are provide including a
Co.sup.2 (58) detector and smoke detector (59). Security detectors
(61) are ready for installation at typical locations i.e. (doors,
windows). All detectors are controlled by the automation system.
The automation system has the ability to shut off services (i.e.
gas, water), turn on fans to vent (i.e. gas), to signal audible,
visual, mechanical alarms or notify third party services such as
the fire department, police department, a security company,
etc.
[0055] ENERGY CONSERVATION--By combining all of the mechanical
systems together it will be possible to greatly conserve energy by
reclaiming "lost" energy by using heat transfer devices. In typical
construction heat expelled from mechanical devices (i.e. clothes
dyer, oven, refrigerator, or heatpumps) is considered "lost". In
the unit the excess heat would be collected though heat transfer
devices known in the art and used by the unit to preheat or precool
water or air to conserve energy. A geothermal tank system (63) is
also incorporated as the automation system will use the ground
temperature in combination with any of the other devices to
conserve energy by cooling water, air, or mechanical coils to
improve their efficiency. Exterior temperature coils are mounted on
the exterior of the unit which allows the automation system to use
extreme exterior temperature in hot or cold climates to assist in
providing heating or cooling for any of the incorporated devices,
increasing the efficiency of the unit as a whole.
[0056] The lifespan of all mechanical equipment is limited and
dated. New technology will make old units obsolete. The ability to
update a buildings entire mechanical system would allow the
remaining building to be reused and preserved. The unit could be
installed in such a manor that it is not an integral part of the
structure allowing it to be removed and replaced with a new unit.
The old unit could then be recycled.
[0057] A common problem with new or alternative building techniques
is that it is difficult to incorporate the mechanical systems, at
least the trades may provide resistance by increasing fees due to
unknowns and unfamiliar conditions. By self containing the
mechanical and utility systems it allows the use of alternative
building techniques and materials. (i.e. straw bale, adobe, foam
block)
DETAILED DESCRIPTION OF THE DRAWINGS
[0058] FIG. 2, FIG. 3, FIG. 4, FIG. 6, FIG. 7, and FIG. 8 show the
unit installed with other elements. Element (45) shows the location
of a hood for a stove. Element (52) shows the hotwater line
installed on site connecting the unit to the kitchen sink. Element
(53) is the cold waterline installed on site connecting the unit to
the kitchen sink. Element (54) is the gas line installed onsite
connecting the unit to the gas appliances. Element (55) is the
Ventilation duct connecting Element (45) to the Unit
[0059] FIG. 5 is a perspective view looking at the ceiling cavity
of the unit. Element (42) is a fan unit connected to element (41)
to (43). Element (50) is a dryer for the shower/tub.
[0060] FIG. 10 is an axonometric view of the prepared foundation.
The foundation can be used with slab or raised floor construction.
The formwork (51) can be reused or made in mass such as plastic
formwork. This would allow proper installation of site connections,
structural and utility by precut holes and markings as required.
The formwork may be removed to use again or left in place.
[0061] The obvious method of transportation for multiple units
would be on a flatbed truck and craned into place. This method is
preferred if multiple units are to be installed but FIG. 11 is a
diagram of a possible alternative delivery system that would allow
for a single unit to be transported and erected without the use of
a crane. The trailer (62) could be towed behind any vehicle and
brought to the site. Said trailer would have the ability to tilt up
the unit while aligning it with the foundation using human or
mechanical means.
VARIATIONS
[0062] Multiple variations are possible for the unit. Certain
configurations may be more applicable than others depending on the
intended use or specific site/project conditions. The unit may be a
single story or multiple stories. The dimensions of the unit may
very maintaining the unit is transportable. The unit could be
constructed out of any construction material. The unit can be
double loaded (as shown) or single loaded (example: the plumbing
wall is the exterior wall). The unit may or may not structurally
support the adjacent structure. The services can be located above,
below or within the unit. The unit could also incorporate any
mechanical or utility service, not only the specific ones described
in this document.
[0063] The unit may control any data, utility, or service. Items
such as cable, Ethernet, dsl, phone, satellite, wireless data,
detectors, monitoing equipment, etc. shall be apart of this
document.
[0064] An example of a variation of the unit is one with no
plumbing on the exterior wall and the mechanical equipment
underneath the unit may be more efficient in colder climates. The
pipes could freeze in an exterior wall and the other mechanical
equipment would provide enough heat output to keep the mechanical
vault from freezing.
[0065] Another variation is a unit that allows other units or other
systems to be serviced by the Unit acting as a hub or core to the
overall system.
[0066] The unit may also be used in the construction of
milti-residential, hospitality and in healthcare projects due to
the repetition of mechanical and utility systems. For hospitality
the front desk could control the rooms systems from the front desk.
For the healthcare application the nurses station could monitor all
of the incorporated medical equipment.
[0067] The unit may be used for emergency housing for organizations
such as FEMA. A single story simplified version of the unit that
does not incorporate such elements as the automation system.
Appliances and fixtures would be installed and ready for use. The
structure would be made out of a material that could resist
exposure to weather. The smaller size of this unit would allow for
many more to be loaded on a transportation vehicle. This variation
would allow for quick and efficient mechanical and utility support
for emergency shelter. After the emergency use is no longer
required the same units could be made available for reconstructing
destroyed permanent housing.
* * * * *