U.S. patent number 3,593,469 [Application Number 04/883,379] was granted by the patent office on 1971-07-20 for prefabricated service module for a dwelling unit.
This patent grant is currently assigned to General Housing Industries. Invention is credited to Harlin Joseph Wall.
United States Patent |
3,593,469 |
Wall |
July 20, 1971 |
PREFABRICATED SERVICE MODULE FOR A DWELLING UNIT
Abstract
A prefabricated service module for a dwelling unit. A center
wall has a stairway extending upwardly along one side thereof
having space beneath it for a water heater and a powder room. A
floor portion extends laterally from the middle of the other side
which serves as a floor for a bathroom and a ceiling for a kitchen.
The kitchen appliances are arranged along the center wall in the
kitchen space and the bathroom fixtures along the center wall in
the bathroom space. The utility systems, such as heating ducts,
vent ducts, electric supply, water and sewer systems are provided
in the center wall. The entire structure can be completely
prefabricated and can even include all of the appliances, plumbing
fixtures and the like, so that it can be fully tested out at the
point of its manufacture, and thereafter transported to the site of
the building into which it is to be incorporated.
Inventors: |
Wall; Harlin Joseph (State
College, PA) |
Assignee: |
General Housing Industries
(State College, PA)
|
Family
ID: |
25382467 |
Appl.
No.: |
04/883,379 |
Filed: |
December 9, 1969 |
Current U.S.
Class: |
52/27; D25/35;
52/182; 52/236.3; 52/79.1 |
Current CPC
Class: |
E04B
1/34869 (20130101); E03C 1/01 (20130101) |
Current International
Class: |
E03C
1/01 (20060101); E04B 1/348 (20060101); E03C
1/00 (20060101); A47k 003/16 (); E04h 001/12 () |
Field of
Search: |
;52/27,34,35,79,182,185,220,236,234,173 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Faw, Jr.; Price C.
Claims
I claim:
1. A service module for a dwelling unit, comprising a center wall
having spaces within it, a stairway extending upwardly along one
side of the center wall and having the top ending adjacent one end
of said center wall, a stair ceiling along the one side of the
center wall above the stairway and defining a space above the stair
ceiling for accommodation of an air-temperature-changing system, a
floor panel extending laterally from the other side of the center
wall at about the level of the top of said stairway and defining
with said center wall a space above the floor panel for a bath and
a space below the floor panel for a kitchen, at least a part of an
air duct system extending from said space above said stair ceiling
downwardly through said center wall adjacent said one end of said
center wall and extending laterally at least in the direction of
said floor panel beneath said floor panel, a vent system extending
upwardly through said center wall adjacent said air duct system and
having exhaust duct connections for an exhaust fan opening into
said kitchen space, and the bath space generally along the line of
said vent system, an electrical system extending generally upwardly
through said center wall adjacent the vent system and having leads
extending upwardly to said space above said stair ceiling for
connection to an electric air-temperature-changing system, leads
extending into said kitchen space at least for a kitchen range,
leads extending into the space beneath said stairs for an electric
hot water heater, and leads for electrical outlets, a water supply
system extending generally upwardly in the center wall in the space
adjacent the electrical system and having connections opening into
the space beneath the stairway for connection to a hot water
heater, connections opening into said kitchen space for connection
to a kitchen sink, and connections opening into said bath space for
connection to a lavatory, a commode and a tub shower, and a
drainage system in said space with said water supply system and
having a vent stack extending to the top of the center wall and
drainage connections extending into said bath space for a commode,
a lavatory and a tub, and a drainage connection extending into said
kitchen for a sink.
2. A service module as claimed in claim 1 in which said vent system
has a further exhaust duct connection opening into the space
beneath said stairway for an exhaust fan, said water supply system
has further connections opening into the space beneath said
stairway for a commode and a lavatory, and said drainage system has
a further connection opening into said space beneath said stairway
for a commode.
3. A service module as claimed in claim 1 in which said vent system
has a further exhaust duct connection opening into said bath space
adjacent said one end of said center wall for connection to a
clothes dryer vent, said water supply system has connections
opening into said bath space adjacent said one end of said center
wall for connection to a clothes washer, said electrical system has
a lead extending to the bath space adjacent said one end of said
center wall for connection to a clothes washer and dryer, and said
drainage system has a connection extending to the bath space
adjacent said one end of said center wall for connection to a
clothes washer.
4. A service module as claimed in claim 1 in which said water
supply system further has a connection extending into said kitchen
space for connection to a dishwasher, said electrical supply system
has a lead extending into said kitchen space for connection to a
dishwasher, and said drainage system has a connection extending
into said kitchen space for connection to a dishwasher, and said
drainage system has a connection extending into said kitchen space
for connection to a dishwasher.
5. A service module for a dwelling unit, comprising a center wall
having studs with wall panels on opposite faces thereof with spaces
between the studs, a stairway extending upwardly along one side of
the center wall and having the top ending adjacent one end of said
center wall, a stair ceiling along one side of the center wall
above the stairway and defining a space above the stairway and
defining a space above the stair ceiling for accommodation of an
air-temperature-changing system, an upper floor panel extending
laterally from the other side of the center wall at about the level
of the top of said stairway and defining with said center wall a
space above the upper floor panel for a bath, a false ceiling
spaced downwardly from said upper floor panel and defining with
said upper floor panel a false ceiling space and with said center
wall a space below the false ceiling for a kitchen, a face panel
between the free edges of said upper floor panel and said false
ceiling, at least a part of an air duct system extending from said
space above said stair ceiling downwardly through the first stud
space at said one end of said center wall and extending laterally
through said false ceiling space and opening through said face
panel, a vent system extending upwardly through said center wall in
the stud space next adjacent the stud space in which said air duct
system is positioned, said vent system having exhaust duct
connections for an exhaust fan opening into said kitchen space and
said bath space generally along the line of said stud space in
which it is positioned, an electrical system extending generally
upwardly through said center wall in the stud space next adjacent
the stud space in which said vent system is positioned, and having
leads extending upwardly to the space above said stair ceiling for
connection to an electric air-temperature-changing system, leads
extending into said kitchen space adjacent said one end of said
center wall for a kitchen range, leads extending into the space
beneath the lower end of said stairs for an electric hot heater,
and leads for electrical outlets, a water supply system extending
generally upwardly in the center wall in the stud space next
adjacent the space in which said electrical system is located, said
water supply system having connections opening into the space
beneath the stairway for connection to a hot water heater,
connections opening into the kitchen space for connection to a
kitchen sink adjacent said stud space in which said water supply
system is located, and connections opening into said bath space for
connection to a lavatory, a commode and a tub shower, and a
drainage system in said stud space with said water supply system
and having a vent stack extending to the top of the center wall and
drainage connections extending into said bath space for a commode,
a lavatory and a tub, and a drainage connection extending into said
kitchen for a sink.
6. A service module as claimed in claim 5 in which said stairway
has the lower end thereof spaced inwardly from said other end of
said center wall and spaced above the bottom of the center wall,
and a stair landing removably mounted on said center wall and
extending from the bottom of the stairway to said other end of said
center wall, whereby access can be gained to the space under said
stairway by removal of the stair landing.
7. A service module as claimed in claim 5 further comprising a
powder room wall portion extending from said one end of said center
wall beneath the top of said stairway and having a powder room door
therein, a backwall panel extending downwardly from beneath said
stairway defining the backwall of the powder room, and said vent
system has a further exhaust duct connection opening into the space
beneath said stairway for an exhaust fan for said powder room, said
water supply system has further connections opening into the space
beneath said stairway in the corner between said center wall and
said powder room wall portion for a lavatory, and through said
backwall panel for a commode, and said drainage system has a
further connection opening through said backwall panel for a
commode.
8. A service module as claimed in claim 7 further comprising an
outer sidewall over the side of the stairway remote from said
center wall and enclosing said stairway and defining with said
center wall stairway and backwall a powder room space beneath said
stairs.
9. A service module as claimed in claim 8 further comprising a
bottom floor panel attached to the bottom of said center wall and
the bottom of said outer sidewall and forming a bottom for said
service module.
10. A service module as claimed in claim 9 further comprising a
lavatory in the corner of said powder room space defined by said
center wall and said powder room wall portion and connected to said
water supply connections and said commode connection to said
drainage system.
11. A service module as claimed in claim 5 in which said vent
system has a further exhaust duct connection opening into said bath
space adjacent said one end of said center wall for connection to a
clothes dryer vent, said water supply system has connections
opening into said bath space adjacent said one end of said center
wall for connection to a clothes washer, said electrical system has
a lead extending into the bath space adjacent said one end of said
center wall for connection to a clothes dryer, and said drainage
system has a connection extending to the bath space adjacent said
one end of said center wall for connection to a clothes washer.
12. A service module as claimed in claim 11 further comprising a
washer-dryer end panel extending away from said center wall along
said upper floor panel and a washer-dryer side panel extending from
said washer-dryer end panel along the free edge of said upper floor
panel to the said one end thereof to define with said washer-dryer
rear panel a washer-dryer space into which said connections for a
washer and dryer open.
13. A service module as claimed in claim 12 further comprising a
combination clothes washer and dryer in said washer-dryer space
coupled to said washer and dryer connections to the water supply
system, the electrical system, the drainage system and the vent
system.
14. A service module as claimed in claim 5 in which said water
supply system further has a connection extending into said kitchen
space for connection to a dishwasher, said electrical supply system
has a lead extending into said kitchen space for connection to a
dishwasher, and said drainage system has a connection extending
into said kitchen for connection to a dishwasher.
15. A service module as claimed in claim 14 further comprising a
bottom floor panel attached to the bottom of said center wall and
forming a bottom for said service module.
16. A service module as claimed in claim 15 further comprising an
electric kitchen range in said kitchen space adjacent said one end
of said center wall and against said center wall and connected to
the range connection to said electrical supply system, an exhaust
fan above said range and connected to the duct connection in said
vent system which opens into said kitchen space, a dishwasher on
said floor panel next to said kitchen range and against said center
wall and connected to the dishwasher connections of said water
supply system, said electrical system and said drainage system, and
a kitchen sink on said center wall next to said dishwasher and
connected to the sink connections of said water supply system and
said drainage system.
17. A service module as claimed in claim 16 further comprising a
cabinet in which said kitchen sink is mounted, and further cabinets
mounted along said center wall and on the bottom surface of the
false ceiling at least over said range, said dishwasher and said
sink.
18. A service module as claimed in claim 5 further comprising a
bottom floor panel attached to the bottom of said center wall and
forming a bottom for said service module.
19. A service module as claimed in claim 18 further comprising an
electric kitchen range in said kitchen space adjacent said one end
of said center wall and against said center wall and connected to
the range connection of said electrical supply system, an exhaust
fan above said range and connected to the duct connection in said
vent system which opens into said kitchen space, and a kitchen sink
on said center wall connected to the sink connections of said water
supply system and said drainage system.
20. A service module as claimed in claim 18 further comprising
cabinets mounted along said center wall and on the bottom of said
false ceiling.
21. A service module as claimed in claim 18 further comprising an
electric kitchen range in said kitchen space adjacent said one end
of said center wall and against said center wall and connected to
the range connection of said electrical supply system, an exhaust
fan above said range and connected to the duct connection in said
vent system which opens into said kitchen space, a kitchen sink on
said center wall connected to the sink connections of said water
supply system and said drainage system, and cabinets mounted along
said center wall and on the bottom of said false ceiling at least
over said range and sink.
22. A service module as claimed in claim 5 further comprising means
on the opposite ends of said center wall and connected to said
center wall and said upper floor panel for imparting rigidity to
said service module.
23. A service module as claimed in claim 5 further comprising a
full transverse end wall on the other end of said center wall and
extending transversely thereof and extending the full height of
said center wall and being attached to the upper floor panel, and a
partial transverse end wall on the one end of said center wall and
extending transversely thereof, said partial transverse end wall
extending from the bottom of the center wall to the upper floor
panel and extending transversely of the center wall only in the
direction of the upper floor panel and to the free edge of the
upper floor panel.
24. A service module as claimed in claim 23 further comprising a
bottom floor panel attached to the bottom of said center wall and
said transverse end walls and forming a bottom for said module.
25. A service module as claimed in claim 23 further comprising an
outer sidewall over the side of the stairway remote from said
center wall and enclosing said stairway and defining with said
stairway and said center wall a space beneath said stairway, said
outer sidewall having an opening therein for access to the lower
end of said stairway.
26. A service module as claimed in claim 25 further comprising a
bottom floor panel attached to the bottom of said center wall and
said transverse end panels and said outer side panel and forming a
bottom for said module.
27. A service module as claimed in claim 23 further comprising a
top panel attached to the top of said center wall and to the top of
said full transverse end wall and serving as a top for said service
module.
28. A service module as claimed in claim 27 further comprising an
outer sidewall over the side of the stairway remote from said
center wall and depending from the free edge of said top panel and
attached to the free edge of said full transverse end panel and
enclosing the space above said stair ceiling and enclosing said
stairway.
29. A service module as claimed in claim 28 in which said stair
ceiling has an upwardly inclined portion extending parallel to the
steps on said stairway, said upwardly inclined portion being hinged
at the lower end to the remainder of said stair ceiling and being
pivotable downwardly to provide access to the space above the stair
ceiling.
30. A service module as claimed in claim 29 further comprising an
air-temperature-changing system mounted in said space above said
stair ceiling coupled to said air duct system, said service module
including air return passages extending into said space above said
stair ceiling.
31. A service module as claimed in claim 30 in which said center
wall has a further stud space adjacent said other end extending
from said space beneath said stairway upwardly to said space above
said stair ceiling, and said outer sidewall has stud spaces therein
extending upwardly into said space above said stair ceiling and
having openings into said stud spaces from the side facing away
from said stairway.
32. A service module as claimed in claim 5 further comprising an
electric water heater in the space beneath said stairway coupled to
said water heater connection of said water supply system and said
electrical system.
33. A service module as claimed in claim 5 further comprising a
lavatory in said bath space against said center wall and connected
to the lavatory connections of said water supply system and said
drainage system, and a commode next to said lavatory and connected
to the commode connections of said water supply system and said
drainage system.
Description
This invention relates to a prefabricated service module for a
dwelling unit, and more particularly relates to a service module
which contains all of the services and utilities necessary for a
complete dwelling unit and which is compact in form and which can
be easily fabricated, yet will permit a wide variety of dwelling
units to be built with the unit as a core.
Prefabricated portions of dwelling units which contain certain of
the services or utilities necessary for the dwelling unit have long
been of interest, but in recent years such units have become of
greater interest because of the two factors of rapidly increasing
population with the resultant demand for housing which can be
erected rapidly, and the necessity of producing quality housing at
lower cost. The prior art has developed some such units,
principally bathroom or bathroom and kitchen units in which all of
the plumbing has been incorporated in the module which can then be
placed in the dwelling as it is being assembled. There have even
been attempts to incorporate kitchens in such modules.
However, several problems have been encountered which have
prevented widespread acceptance of such modules by the housing
industry. Perhaps foremost among them is the problem of compliance
with building codes for various jurisdictions. It is not difficult
to develop a service module if the requirements of the building
codes are ignored. Of course, such modules cannot be used except in
those areas not covered by such codes.
The second problem is to keep the size of the module down so that
it can be transported from the prefabrication point to the building
site. This is a relatively easy problem to overcome with modules
which are no more than one room or two rooms back to back. However,
such modules usually include only a bathroom, or a bathroom and
kitchen, and are mostly for apartment-type dwellings. Core units
which are to serve for two-story dwellings, such as the so-called
townhouse-type dwelling or even single family dwellings, of course
present much more difficult problems because of the limits of the
width and height of loads which can be transported over public
highways.
The third problem is that of ease and consequent low cost of
assembly. These factors are essential to a successful module, yet
they must not be obtained at the expense of weakening the overall
module or making it less flexible in use.
It is an object of the present invention to provide a service and
utility module for a dwelling unit which overcomes the drawbacks of
all of the prior art modules, yet which can be fabricated easily
and inexpensively in conformity with building codes, has a size
which enables it to be trucked easily to a construction site, and
which is laid out so that it permits great flexibility in the
design of the dwelling unit in which it is to be incorporated.
This object is accomplished by the providing of a structure which
has a center wall with a stairway extending upwardly along one side
thereof having space beneath it for a water heater and a powder
room, and a floor portion extending laterally from the middle of
the otherside which serves as a floor for a bathroom and a ceiling
for a kitchen. The kitchen appliances are arranged along the center
wall in the kitchen space and the bathroom fixtures along the
center wall in the bathroom space. The utility systems, such as
heating ducts, vent ducts, electric supply, water and sewer systems
are provided in the center wall and are arranged in the recited
order starting at the end of the service module at which the upper
end of the stairs is located. The systems are arranged generally
vertically with the horizontally extending branches extending
through spaces available behind the appliances and within the
center wall. The appliances requiring venting are all arranged
along the portion of the center wall where the vent system is
located, and the appliances and fixtures requiring water and
drainage are, with a few exceptions, arranged along the portion of
the center wall near the water supply and sewer systems. The entire
structure can be completely prefabricated and can even include all
of the appliances, plumbing fixtures and the like, so that it can
be fully tested out at the point of its manufacture, and thereafter
transported to the site of the building into which it is to be
incorporated.
Other and further features of the invention will become apparent
from the following description taken with the accompanying
drawings, in which:
FIG. 1 is a perspective view of one end and one side of the
prefabricated service module for a dwelling unit according to the
present invention;
FIG. 2 is a perspective view of the other side and end of the
prefabricated service module;
FIG. 3 is a side elevation view of the prefabricated service module
taken from the side shown in FIG. 2;
FIG. 4 is a side elevation view of the prefabricated service module
taken from the side shown in FIG. 1;
FIG. 5 is a side elevation view of the service module as shown in
FIG. 4 with the near sidewall removed;
FIG. 6 is a sectional plan view taken along section line 6-6 of
FIG. 5, with the stairs removed to expose the space beneath
them;
FIG. 7 is a sectional plan view taken on section line 7-7 of FIG.
5;
FIG. 8 is a sectional end elevation view taken along section line
8-8 of FIG. 3;
FIG. 9 is an end elevation view of the one end of the prefabricated
service module as shown in FIG. 5;
FIG. 10 is an end elevation view of the other end of the
prefabricated service module as shown in FIG. 5;
FIG. 11 is a schematic view of the air circulation system for
heating and cooling air for the prefabricated service module;
FIG. 12 is a schematic view of the electrical system for the
prefabricated service module;
FIG. 13 is a schematic view of the water supply system for the
prefabricated service module; and
FIG. 14 is a schematic view of the drainage and sewage system for
the prefabricated service module.
The basic structure of the prefabricated service module comprises a
framed center wall 30 having studs therein with spaces therebetween
which is shown in section in FIGS. 6, 7 and 8, and the opposite
sides of which are shown in FIGS. 3 and 5. It is preferred that the
studs extend the entire height of the wall to provide unobstructed
spaces for the entire height of the wall.
Extending transversely to one end of the center wall 30 is a full
transverse end wall 31, also shown in section in FIGS. 6 and 7, and
the vertical section of which is shown in FIGS. 3 and 5. At the
other end of the center wall 30 is a partial transverse end wall 32
which extends from the center wall 30 transversely thereof in only
one direction. This is shown in section in FIGS. 6 and 7, and in
elevation in FIGS. 3 and 10. Also, this partial transverse end wall
extends for only one half the height of the full transverse end
wall. The upper end of the full transverse end wall is cut off as
at 31a in FIGS. 1 and 9, and above the partial transverse end wall
32 is a framing 32a, shown clearly in FIG. 10, which extends from
the top of a washer-dryer side panel 52, described in more detail
hereinafter, at an angle parallel to the cutoff corner 31a of the
full transverse wall 31. The purpose of the cutoff portion and the
angle frame piece will be explained hereinafter.
Extending horizontally from the center wall 30 from a point about
half the height thereof is an upper floor panel 33. This upper
floor panel 33 extends only in the direction in which the partial
transverse end wall 32 extends, and substantially fills the space
between the top edge of the partial transverse end wall 32 and the
full transverse wall 31, and serves as a floor for the upper story
of the service module. Extending laterally from the middle of the
height of the center wall 30 and in the opposite direction from the
upper floor panel 33 and on the same end of the service module as
the partial transverse end wall is a horizontal door frame member
32b, and depending from the free edge thereof is a vertical door
frame member 32c, the edge of the partial transverse end wall 32
and the door frame members 32b and 32c defining a door space 62,
all as shown most clearly in FIG. 10.
A bottom floor panel 34 is secured to the bottom edge of the center
wall 30, the full transverse end wall 31, the partial transverse
end wall 32, and the bottom end of the vertical door frame member
32c, and serves as a flooring for the service module. Extending
upwardly from the free end of the horizontal door frame member 32b
is a further vertical door frame member 32c, and extending across
the top of the frame member 32c to the top corner of the center
wall 30 is a further horizontal door frame member 32d, these
elements together defining an upper doorlike opening 62a, clearly
shown in FIG. 10.
In the corner defined by the inner surface of the center wall 30
and that of the full transverse end wall 31 on one side of the
service module, as shown in FIG. 1, there is removably positioned a
lower stair landing 35, which is spaced above the bottom floor
panel 34 a distance of about three or four steps. Extending
upwardly, to the left in FIG. 5, is a stairway 36 having at its
upper end a top or upper stair landing 37 which is on a level with
the bottom edge of the door opening 62 defined by the door frame
members 32c, 32d, and the center wall 30. Spaced above the lower
stair landing, stairs, and upper stair landing is a stair ceiling
generally indicated at 38 in FIG. 5, and having a lower horizontal
portion 38a, and upwardly inclined portion 38b, and a horizontal
upper portion 38c, these portions being parallel to the lower stair
landing 35, the stairs 36 and the upper stair landing 37,
respectively. It is preferred that upwardly inclined portion 38b
has steps 38f or the like on the top side and is hinged at the
lower end thereof to lower horizontal portion 38a by a hinge 38d,
and the upper end is removably attached to the upper horizontal
portion by latch means 38e, so that when the latch means is
unlatched, the inclined portion 38b can be dropped with the free
end resting on the upper stair landing 37 and the steps 38f give
access to the space 39 above the stair ceiling.
It will thus be seen that there has been defined on the one side of
the center wall 30 a stairwell having above it an enclosed space 39
and having below the lower stair landing a further space 40, and
having beneath the stairs a still further space, which will be
described more in detail hereinafter. On the other side of the
center wall 30 there has been defined a lower space 41, hereinafter
referred to as the kitchen space, and an upper space 42, which will
hereinafter be referred to as the bath space.
Referring first to the space 41, which is shown in detail in FIGS.
3, 6 and 8, it will be seen that it has a false ceiling 43 spaced
downwardly from the upper floor panel 33 a short distance, and it
is preferred to provide a plurality of cabinets 44 depending from
the false ceiling 43 along center wall 30, although such cabinets
can be added later. The space between the free edges of the upper
floor panel 33 and the false ceiling 43 is filled by a cover panel
45. In the preferred embodiment, there are spaced along the bottom
floor panel beginning at the partial transverse end wall 32 a
combination range and oven 46, next to which is a dishwasher 47
which is against the end of the combination range and oven 46.
Immediately next to the dishwasher is a kitchen sink 48 having a
garbage disposal 48a therein. Between the kitchen sink 48 and the
full transverse end wall 31 is a stack of drawers 49. Optionally,
louvered doors 50 can be provided in the center wall 30 between two
of the cabinets 44 near the full transverse end wall 31, these
louvered doors opening into the stairwell, as shown in FIGS. 1 and
5. Utility connections for these items are an essential part of the
unit and will be described hereinafter.
In the bath space 42 above the kitchen space 41, as shown in FIGS.
3, 7 and 8, there is provided at the end immediately above the
range 46 a washer-dryer end panel 51 projecting upwardly from the
upper floor panel 33 at a point spaced inwardly from the free end
of the space 42, and on the outer edge of the upper floor panel 33
is a washer-dryer side panel 52. In a preferred embodiment, a
combination washer and dryer 53 is positioned on the upper floor
panel within the space defined by the center wall 30 and the
washer-dryer end and side panels 51 and 52, and these panels extend
upwardly a height somewhat above the top level of the washer-dryer
53. Additional panels (not shown) are provided and shipped with the
service module to the construction site and are there placed on the
top edges of panels 51 and 52 to enclose the washer-dryer space and
separate it from the remainder of space 42.
In a preferred embodiment, a vanity 54 having a lavatory 54a
therein is positioned in the corner of the space defined by the
center wall 30 and the washer-dryer end panel 51. Immediately next
to the vanity is a commode 55, and between the commode 55 and the
full transverse end wall 31 is space 56 to accommodate one end of a
bathtub B indicated in dotted lines. It will be seen that the
bathtub B is to be positioned in this space with the water supply
and drain end adjacent the center wall 30. The bathtub is not
included in the service module because it would project outwardly
therefrom beyond the edge of the upper floor panel 33. It is
installed in the service module after the dwelling has been built
around the service module.
An outer sidewall 70 covers the opposite side of the service
module, as shown in FIGS. 1 and 4, and has a large stairwell
opening at 71 therein which opens out of the lower stair landing 35
and also extends part way up the stairs 36, the top edge being
substantially level with the lower horizontal portion 38a of the
stair ceiling.
In the space beneath the stairs 36, as shown in FIGS. 5 and 8,
there is a water heater space 57 immediately adjacent the space 40
beneath the lower stair landing 35, and accommodated in the space
57 is a water heater 58, preferably an electric water heater. The
edge of the water heater space 57 toward the upper end of the
stairs is closed by a backwall panel 59 for a powder room, and
extending upwardly along the bottom of the stairs is a powder room
ceiling 60, the upper end of which extends horizontally at a
position spaced below the top stair landing 37. A powder room front
wall 61 extends outwardly from the edge of the center wall 30 a
short distance, and there is defined between the free edge thereof
and the vertical door frame member 32c (FIG. 10) the door space 62
for the powder room. It will thus be seen that the powder room is
defined by the spaced center wall 30 and the outer sidewall 70, the
backwall panel 59, the ceiling 60, and the front wall 62. A door 63
is hung on the door frame member 32c. In a preferred embodiment,
there is provided within the powder room against the backwall panel
59 a commode 64, and in the corner between the center wall 30 and
the front wall 61 a lavatory 65.
The space 39 above the stair ceiling 38 is provided to accommodate
an air-temperature-changing system, and in a preferred embodiment
such a heating system, e.g. a furnace 73, preferably an electric
furnace, has a heating air supply duct 74 extending toward the
space between the upper horizontal portion 38c of the stair ceiling
and the top of the service module. The furnace and supply duct are
preferably suspended from a top panel 75 covering the space 39. It
will be understood that the furnace is a forced air furnace, the
intake end of which opens into the space 39, and the output of
which is forced into the supply duct 74 from which the heating air
is circulated through a duct system to be described hereinafter. It
will be further understood that in addition to a furnace, which of
course is an air-heating means, there can be provided an
air-conditioning unit which will cool the air at appropriate
seasons of the year. This can be combined with the furnace 73, and
since such units are well known, a combined unit is not illustrated
here. Should such an air-conditioning unit be provided, it will of
course, be necessary to provide appropriate cooling surfaces and
remote compressor unit, as well as a drain for water extracted from
the air passing through the unit. The compressor connections can be
easily extended down through the space between the surfaces of the
full transverse end wall 31 or outer sidewall 70 and through space
40 to the outside of the dwelling. The drain can be extended to the
drainage system.
It will thus be seen that there has been provided in the service
module appropriate spaces for all of the appliances, plumbing
fixtures, and the heating system which require connections to
service systems of more than one type. For example, the commodes
require a water supply connection as well as a sewage or drainage
connection. The kitchen range requires special power connection as
well as an exhaust ventilation means. The dishwasher requires a
water supply connection as well as drainage connections and
electric power, while the kitchen sink requires both water supply
connection and drainage. The various systems are provided in the
service module with connections at the appropriate spaces for the
various appliances. In the preferred embodiment, the appliances
etc. are actually positioned in the spaces and connected to the
service systems. These systems will now be described.
Referring to FIG. 11, extending transversely from the end of the
supply duct 74 from the furnace 73 are transverse supply ducts 76,
the one ends of which are connected to the supply duct 74 by
antivibration canvas connections 74a. Also connected to the end of
supply ducts 74 through antivibration canvas connections 74a are
downwardly extending air supply ducts 77a and 77b, which extend
down through the first studding space in the outer sidewall 70 and
center wall 30 along the door space at the top of the stairs 36.
The air supply ducts 77a and 77b then extend laterally outwardly
through openings 77c in the outer sidewall 70 as well as 77d in the
cover panel 45 covering the space between the upper floor panel 33
and the false ceiling 43 in the kitchen space.
Also provided are openings 76a in the upper left-hand corner of the
outer sidewall 70 (see FIG. 4) and 76b in the upper center wall 30
(see FIG. 3) which open out of the laterally extending ducts 76. It
will be understood that these openings can either be connected
directly to heating air outlets, or can be connected to further
duct work for heating rooms which are not immediately adjacent to
the service module. All the ends of the ducts are located above the
level of the point at which the ceiling of any adjacent rooms will
come into contact with the service module, and any heating air
outlets appropriately extended downwardly therefrom, for example by
an appropriate elbow 76d, as shown in FIG. 11.
The space 39 above the stair ceiling acts as a main return
air-collecting chamber, access to which is gained through the space
occupied by upwardly inclined ceiling portion 38b shown in FIG. 5.
Opening into this space 39 are return air paths 78 and 79 extending
upwardly through the outer sidewall panel 70 in the studding space
immediately next to the air supply duct 77a. These return air ducts
extend upwardly from the bottom of the outer sidewall 70, having an
air return opening 78a at the lower end thereof. Additional air
return opening 80 is also provided in outer sidewall 70 opening
into the space 57 for accommodating the water heater. A further air
return path 81 extends upwardly through the studding space in
center wall 30 at the end thereof adjacent the full transverse end
wall 31, from the space 40 beneath the lower stair landing 45 into
the space 39 above the stair ceiling. Extending into the space 40
beneath the lower stair landing 35 through the center wall is also
a duct 81a from the panel at the bottom of the drawers 49 in the
kitchen space 41. This provides a return for the kitchen space.
It will thus be seen that a complete circulation system for the
heated or cooled air is provided, the studding spaces within
certain of the walls providing room for the air supply ducts as
well as the air return ducts, and the space around the water heater
also being connected to the circulating air system.
An air exhaust or vent system is also provided for the various
spaces and appliances which require them. The vent stack 83 (see
FIGS. 6 and 7) extends upwardly through the center wall 30 in the
studding space next to the downwardly extending air supply duct
77b, the vent stack 83 extending just above the level of the range
top 46 in the kitchen upwardly through the top panel 75. A kitchen
exhaust fan duct connection is provided in wall 30 from the vent
stack 83 at a level just below the bottom of cabinets 44. In the
preferred embodiment there is mounted below wall cabinets 44 above
the range 46 an exhaust hood, shown schematically at 84 in FIG. 6,
having an exhaust fan (not shown) and an exhaust pipe 84z connected
to the duct connection, so that the exhaust fan discharges into the
vent stack 83 which is immediately behind the range in the center
wall 30. A further exhaust fan duct connection is positioned in
wall 30 beneath the top stair landing 37 and opens into the powder
room. In a preferred embodiment exhaust fan 84 is mounted in the
wall and coupled to this connection so that it discharges into the
vent stack 83 which is also adjacent thereto in the center wall 30.
The bath space 42 also has an exhaust fan duct connection therein
for an exhaust fan shown at 85 in FIGS. 3 and 7, which also vents
into the vent stack 83, which is immediately adjacent thereto. An
exhaust duct connection 53a for the washer and dryer 53 is provided
which opens into the vent stack in the center wall 30, which is
immediately adjacent to the space for the washer and dryer 53. It
will thus be seen that exhaust duct connections for all of the
appliances which require exhaust vents are positioned along wall 30
immediately adjacent the space in which the vent stack 83 extends
upwardly through the center wall 30, and the appliances themselves
are positioned in the service module for easy connection to these
exhaust duct connections.
As shown in FIG. 12, the electrical circuit includes a panel box 90
which fits behind a panel 90a in the powder room, shown in FIG. 5,
in the studding space next to the vent stack 83. Extending into the
panel box is a power line 91 which is to extend to connect to the
power supply from outside the dwelling. Schematically represented
as extending upwardly through the same studding space are wires 92
for such things as the exhaust hood fan 84, the washer and dryer
53, the vent fan 85 for the bath space 42, and the vent fan 84a for
the powder room. Wires 93 are representative of the power supply
leads for such things as the range 46, dishwasher 47, and the water
heater 58. The leads 94 are representative of the power leads for
the furnace and the furnace controls. Leads 95a and 95b are
representative of the leads for the various lighting fixtures and
power outlets throughout the module as well as the remainder of the
dwelling around the module. All of the leads extend to the spaces
for the various appliances to be supplied with power and where
necessary extend laterally through available laterally extending
spaces, such as the space between floor panel 33 and false ceiling
43, or behind the dishwasher 47 and range 46. In the preferred
embodiment, the leads are connected to the actual appliances. It
will be noted that the basic pattern of the leads is vertical
within the studding space, only the ends of the leads extending
outwardly of the space. In this way, this studding space is made
use of for most of the electric power supply circuits in the
module.
The water supply system, as shown in FIG. 13, includes the
connection to the water supply main, shown at 96, and the pipes
which lead to the water heater 58 from the main supply pipe 97. The
connection to the water heater is not visible in FIG. 12, the water
heater being in front of the portion of the system as shown. A hose
bib 97a can be connected to the main supply line to extend through
the full transverse end wall 31 to the outside of the dwelling.
Extending off the main supply and appropriately connected with the
hot water heater are cold water lines for connection to the faucets
at the kitchen sink 48 and for connection to the faucets at the
lavatory 65 in the powder room. These are laterally extending pipes
and are in the space behind the kitchen sink 48. In the preferred
embodiment the kitchen sink faucets 98 and the lavatory faucets 99
will be connected to these lines. Appropriate lines from the hot
water heater also extend to the faucets 98 and 99, and a branch 100
is provided for connection to the water inlet for the dishwasher
47, and which in the preferred embodiment is actually connected to
the dishwasher 47.
Appropriate hot and cold water lines 101 extend vertically through
the space between the studs adjacent the space containing the
electrical supply, and at the top thereof, in the space between the
upper floor panel 33 and the false ceiling 43, extend laterally. A
branch 102 extends to the location of the commode 55 in the bath
space 42, and appropriate lines extend to the valves for a tub
faucet 103 and the shower head 104. Further branches extend to the
faucets 105 for the lavatory 54a in the bathroom vanity 54. Washer
hoses 106 extend from hose bibs 106a beneath the vanity for the
lavatory 54a to the space for the washer and dryer 53 for
connection to the washer and dryer.
It will be seen that the only pipes extending from the lower
portion of the service module to the upper portion are pipes 101,
which utilize a studding space not occupied by any other system,
and where the pipes extend vertically in the remainder of the
system, for example to the bathtub faucet and the shower head, they
are also utilizing studding space or other space not utilized by
other systems. The pipes to the bathtub faucet and shower head
utilize the studding space above the louvered doors 50. An
additional branch, not shown, carries cold water to the commode 64
in the powder room.
The sewage and drainage system, as schematically shown in FIG. 14,
as a connection 107 for connecting to the outside sewer system, the
connection having an access head 108 thereat. A horizontally
extending header extends to the foot of a vertical main vent and
collection pipe 109, to the lower end portion of which is connected
the drain 110 for the kitchen sink 48. Also associated with this
drain system 110 is a drain line 110a extending from the drain
outlet of the dishwasher 47 to the garbage disposal 48a.
At the level of the upper floor panel 33, the main vent and
collection pipe 109 has connected thereto the drain pipe system 111
for the bathtub and the drain 112 for the commode 55. Also
connected at this point is the drain system 113 which serves the
bathroom sink 54a, and the drain 114 for the washer-dryer.
Connected to the drain condensate therefrom.
Immediately adjacent the main vent and collection pipe 109 is a
secondary drain and vent pipe 116 into which the drain system 110
for the kitchen sink has connected a vent pipe. Also branching from
this secondary vertical pipe 116 is a pipe 117 to the drain for the
lavatory 65 in the powder room. Connected to the main horizontal
pipe 107a is the drain 118 for the commode 64 is the powder room.
It is noted that the secondary pipe 116 connects into the main pipe
above the connection for the drain systems 111 for the bathtub, 112
for the bathroom commode, and 113 and 114 for the bathroom sink and
washer-dryer. This enables venting of the kitchen sink and the
powder room lavatory independently of the main collection pipe 109
below the connection for the upstairs plumbing fixtures. The top of
the main pipe 109 opens to a vent at the top of the system.
All of the vertical pipes extend upwardly through the studding
space allowed for the water supply and plumbing system, while the
horizontal pipes extend through spaces otherwise unoccupied. The
horizontal pipes and the upstairs portion of the system extend
through the space beneath the upper floor panel 33 and above the
false ceiling 43, while the laterally extending pipe to the
lavatory in the powder room extends through the studding spaces
below the point where the vent 83 and the air supply ducts 77b
terminate.
In the space between upper floor panel 33 and false ceiling 43 can
be provided connections, not shown, in the water supply and
drainage systems for connection to a remote half bath.
It will be seen that the entire service module is arranged so that
it can be completely prefabricated in a large assembled building,
and, in its preferred embodiment, with all appliances, plumbing
fixtures, etc., in place, all of the systems, appliances and
fixtures are connected to each other, and the entire appliance and
plumbing system can be checked out. The thus prefabricated service
module can then be transported to the site where it is to be
assembled into a dwelling.
It is within the scope of the present invention, however, to
provide the service module without the various appliances, plumbing
fixtures, etc. in place, i.e. to provide the structural elements,
such as the walls, stairway, and the like, and the service systems,
such as the air duct system, the vent system, the electrical
system, and the water supply and plumbing system, and appropriate
connections to enable the various appliances and plumbing fixtures,
etc. to be placed in the service module and connected up at the
building site. Obviously, the service module could also be provided
with some of the appliances and plumbing fixtures and not
others.
It is also within the scope of the present invention to omit from
the structural elements the full transverse end wall 31 and the
outer sidewall 70 covering the stair space, these structural
elements being provided by existing or later built walls at the
building site. Likewise the bottom floor panel and the top panel 75
can also be omitted and supplied by the builder at the building
site, provided that none of the fixtures or appliances which are
supported by these panels are provided. However, if any of these
structural elements are omitted, it will of course be necessary to
provide appropriate bracing to give strength and rigidity to the
service module to enable it to be handled during transportation and
incorporation into the building structure at the site.
Because the service module is a two-story structure, it is
necessary to take certain steps in the transportation in order to
comply with the height limitations for loads which can be
transported on public highways. In actual practice, a special
trailer is provided in which the service module can be tilted
toward the outer sidewall 70 so that the entire module is at an
angle to the vertical and the cutoff portion 31a of the full
transverse end wall 31 is substantially horizontal. With
conventional dimensions for a two-story structure, when the
structure is thus tilted, it does not exceed the height limitations
normally set for hauling of loads on public highways.
With respect to width limitations for transport on public highways,
it has been found that the dimension of the module from end to end
can be made as small as 9 feet 6 inches, which is small enough to
enable it to be carried with its long dimension transverse to the
direction of movement. Several modules can thus be partially
overlapped in the tilted position for transportation on a
trailer.
When the prefabricated service module reaches the site of the
dwelling, it is placed in position on an already prepared slab or
other foundation in which appropriate electrical, water supply and
drainage connections are available.
The module is positioned so that these services can be connected to
the corresponding systems in the module, and thereafter a dwelling
structure is built around the service module. It will be understood
that several steps S, seen in phantom lines in FIG. 5, must be
added in front of the lower stair landing 35. These can be arranged
so as to be directed outwardly away from the stair landing, the
steps thus being at right angles to the stairs 36, or a further
extension of the lower stair landing can be added and the steps
directed in the opposite direction from the stairs 36. A living
room of any reasonable dimension can be built in the direction away
from the stair landing, and a corridor is provided along the end of
the service module toward which the door 63 to the powder room
opens. On the other side of the service module, a kitchen K, also
shown in phantom lines, can be built extending away from the
service module a short distance, in the case of an apartment-type
kitchen, or a relatively great distance for a single family
dwelling where a large kitchen-dining area is desired. On the upper
level of the dwelling, the bath space 42 can be extended as at BR a
smaller or greater distance as desired, the dimension in the
direction away from the service module being sufficient in every
instance to accommodate the full length of the bathtub B. Again, a
corridor must be provided along the end of the service module
toward which the washer-dryer opens, and the door at the top of the
stairs 36 opens. One or more bedroom spaces can be provided in the
direction extending away from the service module from the outer
sidewall 70. Appropriate extensions can be placed on the heating
duct system and the electrical system to provide heated and cooled
air to such rooms and to provide electrical power through
conventional outlet. The service module can thus be a center or
core for wide variety of floor plans, and can be used in duplex
apartments, townhouse-type structures, or single family units. The
entire module can be made in a mirror image to the module shown,
i.e. the stairs can go up from left to right as seen in FIG. 1, and
the other parts appropriately repositioned, although always being
in the same relative position. This makes possible an even greater
variety of floor plans for the space around the module.
A number of advantages will be immediately apparent from the
foregoing description of the service module. The obvious advantages
of being able to prefabricate such a service module in a large
building structure and the benefits which flow from such a
possibility need little description. However, the benefit of being
able to completely test out already installed appliances and
systems such as plumbing, hot water supply, and electrical systems
are not quite so obvious. The difficulties with subcontractors
installing such systems in dwelling at the site are well known, and
these disadvantages are completely overcome in the preferred
embodiment of the present invention in which the systems are
complete and ready to operate at the time the service module
arrives at the site.
Particular advantages of the structure are many. In the first
place, the lower stair landing 35 is made so as to be removable,
thereby providing access to the space beneath this landing and the
lower portion of the stairs for servicing of the water heater, and
to enable workmen initially to make the connections of the systems
of the module to the connections on the foundation or slab. This
space also serves as a collecting chamber for return air. Because
the space around the water heater is connected to the space 40
beneath the lower stair landing, it also becomes part of the return
air system, thus promoting circulation through this space to avoid
buildup of heat around the water heater.
The arrangement is such that it must be moved into position
generally horizontally across a foundation or slab. This makes it
desirable to place all of the slab connections in a pit in the slab
so that they do not project above the level of the slab. This
avoids damaging them during positioning of the module on the slab,
and also provides a drainage pit for the overflow from the water
heater. In addition, it provides additional space for the
plumbing.
The positioning of the dishwasher relative to the sink makes
possible the provision of a space behind the dishwasher which is
interconnected with the space beneath the lower stair landing 35.
This makes it possible to pull the main power line from the main
electrical panel into the space beneath the lower stair landing
after positioning the service module on the slab. This is a
considerable cost saver, avoiding the necessity of an intermediate
junction box under the lower stair landing.
The position of the sink and dishwasher in the kitchen space is
further required by the drainage and vent stack locations, which
are limited in the plan position by the maximum horizontal distance
from the lavatory in the powder room to the vent stack as
established by the National Plumbing Code. The vent stack cannot be
moved any further away than it is positioned and still comply with
the code. Likewise, the lavatory cannot be moved because it would
be too far under the sloping ceiling 60 beneath the stairs 36. Thus
these two portions of the module are interrelated and their
positions fixed.
The horizontal plan arrangement of the stove, vent hood therefor,
and the dryer and exhaust fans on the first and second floor is
interrelated to the vertical arrangement of the vent duct. The vent
duct must be in the position as shown, and the other elements in
their relative positions so that it can serve as a common exhaust
for the appliances and fans. The common vertical stud space is
utilized for both the vent system and the heating and
air-conditioning duct, the vent widening below the end of the
heating and air-conditioning at the level of the upper floor panel
in order to connect with the exhaust hood from the range.
The use of the antivibration canvas connections between the supply
air duct from the furnace and the air supply ducts in the various
walls and panels accomplishes three results. It permits the air
supply duct 74 to be rigidly connected to the furnace for
preassembly and positive alignment in handling. Secondly, it serves
as a physical absorption isolator to reduce the transmission of
sound by conduction through the ducts in the different rooms in the
dwelling unit. Thirdly, it functions to make possible correction of
minor misalignment of the air handling unit, i.e. the furnace,
etc., and the sidewalls of the center wall 30 and the outer
sidewall 70 to permit the furnace unit and supply duct to slide
into space between the two assembled walls.
The module also permits the use of balloon framing, which reduces
the shrinkage factor parallel to the grain of the wood because the
framing extends from the bottom of the first floor to the top of
the second floor. This, of course, is made possible by the fact
that the walls can be assembled in the horizontal position and then
raised during the prefabrication. Strength is further added by the
use of attaching the dry wall covering for the various walls with
adhesives in continuous two-story pieces. This increases the
necessary rigidity of the entire module during transportation and
positioning operations.
* * * * *