Apparatus for and method of constructing, transporting and erecting a structure of two or more stories comprised of a plurality of prefabricated core modules and panelized room elements

• US 4,513,545 A
• Filed: 09/20/1982
• Issued: 04/30/1985
• Est. Priority Date: 09/20/1982
• Status: Expired due to Fees

• Current Assignee: George D. Hopkins Jr
• Original Assignee: George D. Hopkins Jr
• Inventors: Hopkins, George D. Jr.
• Primary Examiner(s): Friedman, Carl D.
• Application Number:
  US06/419,732
• Time in Patent Office: 953 Days
• Field of Search: 52/79.1, 52/236.3, 52/221, 52/79.14, 52/236.5, 52/236.6, 52/745
• US Class Current: 52/79.1
• CPC Class Codes: E04B 1/348 Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
• CPC Class Codes: E04B 1/34869 Elements for special technical purposes, e.g. with a sanitary equipment
• CPC Class Codes: E04B 2001/34892 Means allowing access to the units, e.g. stairs or cantilevered gangways
• CPC Class Codes: E04H 1/02 Dwelling houses; Buildings for temporary habitation, e.g. summer housessmall erections for limited occupation E04H1/12 ; collapsible, erectable or rotatable buildings E04B1/343

Abstract

A prefabricated structure of at least two stories comprised of a vertically stacked modular core and interlocking system of panelized component room elements erected upon a monolithic concrete slab. The subject modular core is composed of three units each built upon a base pallet and featuring pre-finished walls, cabinets, appliances, fixtures, floor coverings and containing an integrated plumbing, mechanical and electrical system which services the dwelling. Said core modules and plurality of room elements are manufactured utilizing mass production techniques and transported to the building site. The lower core module contains a kitchen, central hallway, a portion of the staircase, and powder room facilities. Panelized room elements appended to the front and rear of the lower core form a living room and dining/den area. The middle core unit contains a bath with laundry facilities and corridor for internal circulation between two bedrooms subsequently formed by panelized room elements appended to the front and rear sides. The upper core module forms a floored attic area containing heating and air-conditioning equipment and hot water heater. The concrete slab foundation contains a preformed central depression to receive the lower core module thus providing a uniform interior floor surface by receiving pallet of said module. Said preformed depression branches outward from the core extending to the rear exterior wall in the form of a trough which enables the subsequent connection of plumbing drain pipes, water lines and electrical conduit following erection of the structure. A complex of similar dwelling units can be established by placing a plurality of said structures side-by-side, in a linear configuration, thus forming a row of townhouses or offices.

Claims

1. A prefabricated dwelling, having at least two stories comprising:

a. a plurality of prefabricated four-wall non-identical core modules, containing substantilaly all electrical, mechanical and plumbing components necessary to serve said dwelling, said core modules being adapted to be vertically aligned with each other;

b. a base pallet in a lower core module adapted to be received in a preformed monolithic concrete slab, which is provided with a preformed depression to receive said pallet and external utilities connectable with electrical and plumbing lines contained by said core modules;

c. a plurality of pannelized room elements, which interlockingly attach to said core modules to thereby complete said prefabricated dwelling.

2. The apparatus of claim 1, wherein said core modules each comprise a base pallet having an upwardly extending substructure integral thereto, wherein each said substructure cooperates with another of said substructures to form a module superstructure which is received by said concrete slab.

3. The apparatus of claim 2, wherein said panelized room elements interlockingly attach to said superstructure, to thereby complete said prefabricated structure.

4. The apparatus of claim 3, wherein said core modules comprise a lower core module, a middle core module, and an upper core module, wherein said lower core module is received by said concrete slab, said middle core module is vertically aligned with and stacked upon said lower core module, and wherein said upper core module is vertically aligned with and stacked upon said middle core module.

5. The apparatus of claim 4, wherein said upper core module comprises at least a portion of the roof for said structure and a floored attic area.

6. The apparatus of claim 5, wherein said floored attic area contains mechanical equipment for servcing said structure.

7. The apparatus of claim 6, wherein said mechanical equipment comprises, at least in part, air-conditioning and heating equipment for servicing said structure.

8. The apparatus of claim 7, wherein all of said core modules and said panelized room elements have at least one dimension of 8'"'"' to facilitate utilization of standard-size construction materials.

9. The apparatus of claim 1, wherein one of said single, vertical walls formed by said stacked core modules comprises all plumbing connections necessary for water, sewage and drainage service for said structure.

10. The apparatus of claim 1, wherein said preformed trough depression of said concrete slab is of the same height as said base pallet of said lower core module which it receives, thereby providing a uniform floor level for said structure.

11. The apparatus of claim 10, wherein each of said core modules comprise elements of plumbing, electrical and/or mechanical systems which operatively cooperate with each other by means of pipe and duct connections provided at the points of intersection between said modules.

12. The apparatus of claim 11, wherein said base pallet of said lower core module comprises a service chase from which said plumbing system servicing said structure emanates, thus allowing manufacture and preassembly of said plumbing system integrated into said modules at a location remote from the building site.

13. The apparatus of claim 1, wherein said concrete slab further comprises a second preformed trough depression equal in depth to said preformed depression for receiving said lower core module, for facilitating connection of said plumbing system servicing said structure from said base pallet of said lower core module to the exterior of said structure, thereby facilitating completion of said plumbing system after erection of said structure.

14. The apparatus of claim 1, wherein said structure is provided with a staircase comprised of first and second components wherein said first component comprises a first staircase which is prefabricated as an integral part of said lower core module and wherein said second component comprises a second staircase which is separately prefabricated for attachment during the course of erection of said structure, said components thence cooperating to complete said staircase for said structure.

15. The apparatus of claim 14, wherein said floored attic area of said upper core module further contains a hot water heater.

16. The apparatus of claim 15, wherein said lower core module comprises a fully furnished, self-contained kitchen having a corridor for internal circulation.

17. The apparatus of claim 16, wherein said lower core module further comprises a powder room.

18. The apparatus of claim 17, wherein said kitchen contains a refrigerator, an electric range, a double-pan sink, a dishwasher, base cabinets/drawers having countertops, and upper cabinets.

19. The apparatus of claim 18, wherein said powder room contains a toilet and a laboratory.

20. The apparatus of claim 19, wherein said middle core module comprises a full bathroom, laundry facilities, linen closet and chases for air conditioning supply, return air and wiring.

21. The apparatus of claim 20, wherein said bathroom of said middle core module contains a bathtub/shower, a toilet, a vanity base cabinet, a lavoratory mounted within said vanity base cabinet.

22. The apparatus of claim 21, wherein all fixtures and appliances requiring plumbing are located within said lower, middle and upper core modules.

23. The apparatus of claim 22, wherein all of said fixtures and appliances requiring plumbing which have been located within said lower, middle and upper core modules, are further grouped within said lower, middle and upper core modules so as to be aligned vertically and be placed side-by-side horizontally, thus minimizing plumbing complexity.

24. The apparatus of claim 23, wherein said panelized room elements are comprised of at least three different types thereof, including insulated, pre-wired wall, roof and floor room elements.

25. The apparatus of claim 24, wherein said lower, middle, and upper core modules comprise an integrated electrical wiring system which connects with said pre-wired wall elements, to thereby provide electrical utility service to said structure.

26. The apparatus of claim 25, wherein said panelized wall elements are pre-finished on at least one side thereof.

37. The apparatus of claim 1, wherein said core modules extend substantially the width of said structure and said panelized room elements are attached to the front and rear walls of said core modules.

27. The apparatus of claim 27, wherein said lower, middle, and upper core modules comprise a system of ducts which align and operatively cooperate with each other, and which connect to said air-conditioning equipment contained by said floored attic area of said upper core module, thereby providing a pre-fabricated air-conditioning and heating system for said structure, without the necessity of on-site preparation to facilitate installation thereof.

28. The apparatus of claim 27, wherein said insulated, pre-wired wall, roof, and floor room elements interlockingly attach with each other and with said lower, middle, and upper core modules, to thereby form a plurality of rooms adjacent to either side of said lower, middle, and upper core modules.

29. The apparatus of claim 28, wherein said insulated, pre-wired wall room elements comprise perpendicular and parallel types, wherein said perpendicular wall elements interlockingly attach to said lower, middle, and upper core modules, and wherein said parallel wall elements are interconnected between said perpendicular wall elements, to thereby form the exterior walls for said rooms formed by said insulated, pre-wired wall, roof, and floor room elements.

30. The apparatus of claim 29, wherein said insulated, pre-wired floor room elements are comprised of outer and inner elements, wherein said inner and outer floor room elements are interlockingly attached to each other along the lengths thereof, and wherein said floor room elements are interlockingly attached to said lower, middle, and upper core modules on their inner ends, and interlockingly attach to said parallel wall room elements on their outer end, thereby forming the roof/ceiling for the room formed by said wall room elements to which they interlockingly attach, and thereby simultaneously forming the floor for the room subsequently constructed thereabove.

31. The apparatus of claim 30, wherein said base pallets of said lower, middle and upper core modules each comprise a plurality of joists to which said perpendicular wall room elements, said roof room elements and said outer and inner floor room elements interlockingly attach.

32. The apparatus of claim 31, wherein said joists are composed of metal.

33. The apparatus of claim 32, wherein said joists are composed of wood.

34. The apparatus of claim 33, wherein said lower core module comprises an electrical distribution panel and a vertical chase, and wherein said middle and upper core modules comprise second and third vertical chases in alignment with said vertical chase of said lower core module, wherein all of said chases are disposed directly below said mechanical equipment located in said floored, attic area of said upper core module, thereby facilitating the installation of electrical wiring therethrough, to thereby provide electrical utility service to said structure.

35. The apparatus of claim 34, wherein said base pallet of said lower core module comprises a service chase for receiving pre-wired electrical circuits, receptacles, switches, appliances, equipment, lighting, vents, fans, and electrical distribution panels, thus eliminating on-site preparation of electrical utility service systems for said structure.

36. The apparatus of claim 35, wherein said monolithic concrete slab further comprises a third preformed trough depression, having the same height as said trough depression of said slab for receiving said lower core module, for thereby facilitating the connection of electrical wiring from said service chase of said base pallet of said lower core module to the exterior of said structure.

38. A method of constructing a multi-story dwelling, which comprises the steps of:

a. prefabricating a plurality of four-wall non-identical core modules, said modules containing substantially all electrical, mechanical and plumbing components, servicing said dwelling;

b. prefabricating a plurality of panelized, prewired room elements adapted to be interlockingly connected with said core modules to form the dwelling;

c. providing a monolithic concrete slab with preformed depressions to receive a pallet of a lower core module and electrical and plumbing lines for connecting them to external similar utilities;

d. setting said lower core module into said preformed depression in said slab;

e. connecting a middle core module with said lower core module by vertically mounting it atop said lower core module;

f. connecting an upper core module to the middle core module by vertically aligning it and mounting it atop said middle core module;

g. interlockingly attaching said panelized room elements to pallets and joists provided by said core modules;

h. connecting said electrical, mechanical and plumbing lines provided by said core modules to said panelized rooms and to external utilities via lines provided in said preformed depressions in said slab.