Abstract:
A prefabricated housing component that includes at least one casting having a wall portion, a floor portion, a ceiling portion, wherein the wall portion, floor portion and ceiling portion cooperate to form an interior space, and a cabinet portion including a recessed portion within the interior space. The prefabricated housing component further includes a framework surrounding the casting, wherein the framework provides structural rigidity thereto.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This application claims priority from U.S. Provisional Patent Application No. 60/359,403, filed on Feb. 23, 2002, entitled PREFABRICATED HOUSING COMPONENTS. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates to the housing industry and, in particular, to prefabricated components such as bathrooms and kitchens which are preferably built at a factory and shipped to a build site.  
           [0003]    The housing construction industry is one of the largest sectors of the United States economy. In the construction industry there is considerable competition to continually produce an improved product, reduce costs, and speed construction. One way for a builder to reduce costs is to purchase less expensive materials. However, this approach often leads to an inferior product or building. Another approach to reducing costs is to reduce the amount of labor required to produce a house or building. This is accomplished by the use of continually improving tools such as nail guns, power tools, and the like. Labor is also reduced by the use of ready to install, standardized, or pre-ordered moldings, wall panels, trusses, floorings, trim, and the like. However, labor continues to be a significant cost of a house or building.  
           [0004]    One aspect of the labor costs is associated with the electrical and plumbing work that must be done on site. The electricians and plumbers are skilled at their craft, but may cause a delay if they are not able to perform their work under a schedule desired by the builder. Further, government inspectors may be required to inspect the electrical and plumbing work before the drywall or other work can continue. Thus, delays or possible problems may delay construction and increase costs.  
           [0005]    Another aspect of the construction industry is to increase the value and desirability of a building by including innovative, attractive, and more durable features. The continuing goal, therefore, is to find ways to reduce costs, increase durability and functionality, improve the aesthetic appeal, and improve efficiency.  
         SUMMARY OF THE INVENTION  
         [0006]    To address the goals stated above and other goals, the inventive prefabricated housing components are manufactured using large-scale composite molding techniques to form wall, ceilings, floors, cabinets, and other features from a single casting. In the preferred embodiment, an entire room, such as a bathroom or a kitchen, is formed from only two such castings. The two castings are mated together and aligned with alignment pins to form a single unit. Support ribs are attached to the exterior of the casting. A framework, preferably made of wooden or metal studs, is constructed to enclose the casting. The casting is placed inside of the framework and the support ribs secure the casting to the framework while the casting continues to cure. The studs are then more securely attached to the casting by use of a composite material, mechanical fasteners and structural components, thereby increasing the structural resiliency and rigidity of the final structure.  
           [0007]    Various portions of the casting are cutout to provide apertures for such things as medicine cabinets, towel cabinet drawers and doors, vanity doors and doors, plumbing access and electrical devices and switches. The component is then finished by connecting plumbing and electrical devices, adding doors, and drawers, installing flooring, sinks, counter tops, towel racks, and the like to complete the component.  
           [0008]    The component is then shipped to the building site where the component is installed in place. The high strength of the component reduces the chance of damage during the shipping process. The plumbing and electrical work is done at the factory where it is also inspected. The work is completed indoors and can therefore be done efficiently regardless of outside weather conditions.  
           [0009]    Finally, the unique construction technique of the invention permits aesthetically pleasing and useful shapes and designs that are not typically available using conventional construction techniques. For example, the molded construction technique permits the application of various curves and sculptured shapes. Rectangular cabinets and 90° corners may be replaced with smoothly sculptured cabinets and rounded comers. The possibility of designs is virtually limitless.  
           [0010]    In some applications, an additional casting may be used when it is not practicable to use only two castings. For example, in a bathroom application, a tub/shower casting may be molded separately and installed into the component after the initial two halves are assembled.  
           [0011]    One aspect of the present invention is to provide a prefabricated housing component that comprises at least one casting including a wall portion, a floor portion, a ceiling portion, wherein the wall portion, floor portion and ceiling portion cooperate to form an interior space, and a cabinet portion including a recessed portion located within the interior space. The prefabricated housing component further includes a framework surrounding the casting, wherein the framework provides structural rigidity thereto.  
           [0012]    Another aspect of the present invention is to provide a method of manufacturing a prefabricated housing component that includes the steps of applying a composite material to a mold that includes a wall portion, a ceiling portion and a floor portion, allowing the composite material to at least partially cure, thereby resulting in a casting, and removing the casting from within the mold. The method further includes inserting the casting into a cavity as defined by a framework, and securing the casting to the framework.  
           [0013]    It is clear that the invention is a significant improvement over the prior art systems. Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described in the detailed description which follows, the claims, as well as the appended drawings.  
           [0014]    It is to be understood that the foregoing description is exemplary of the invention only and is intended to provide an overview for the understanding of the nature and character of the invention as it is defined by the claims. The accompanying drawings are included to provide a further understanding of the invention and are incorporated and constitute part of this specification. The drawings illustrate various features and embodiments of the invention which, together with their description serve to explain the principals and operation of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    [0015]FIG. 1 is a cutaway top perspective view of a casting embodying the present invention, wherein the casting comprises a bathroom;  
         [0016]    [0016]FIG. 2 is a front elevational view of a vanity, a medicine cabinet, and a towel cabinet of the bathroom of FIG. 1;  
         [0017]    [0017]FIG. 3 is a top plan view of the bathroom of FIG. 1;  
         [0018]    [0018]FIG. 4 is a top plan view of a recessed portion and an insert cut away to show an interlocking joint;  
         [0019]    [0019]FIG. 5 is a front elevational view of the recessed portion of the casting;  
         [0020]    [0020]FIG. 6 is an exploded perspective view of the castings and framework associated therewith;  
         [0021]    [0021]FIG. 7 is a cross-sectional side elevational view along section VII-VII, FIG. 1;  
         [0022]    [0022]FIG. 8 is a top perspective view of a stud, a support rib, and a bracket according to the invention;  
         [0023]    [0023]FIG. 9 is a top perspective view of an insert according to the invention;  
         [0024]    [0024]FIG. 10 is a cross-sectional side elevational view of an alignment pin and an associated flooring;  
         [0025]    [0025]FIG. 11 is a cross-sectional top plan view of a wall of the casting;  
         [0026]    [0026]FIG. 12 is a cross-sectional view of a strengthened portion of the casting;  
         [0027]    [0027]FIG. 13 is a cross-sectional view of the floor and the wall of the casting;  
         [0028]    [0028]FIG. 14 is a top plan view of an alternative casting of the present invention, wherein the alternative casting comprises a kitchen;  
         [0029]    [0029]FIG. 15 is a cross-sectional side elevational view of a lower drain pan;  
         [0030]    [0030]FIG. 16 is a top perspective view of a bath/shower casting;  
         [0031]    [0031]FIG. 17 is a side elevational view of the housing component supported by a trolley assembly; and  
         [0032]    [0032]FIG. 18 is a perspective view of the trolley assembly. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0033]    Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.  
         [0034]    An exemplary embodiment of a prefabricated housing component according to the present invention is shown in FIG. 1, and is designated generally throughout by reference numeral  10 . Parts of the prefabricated housing component  10  of the present invention will first be briefly described and then described in detail. The most common use for the invention is as a bathroom or kitchen for a home, a duplex, an apartment, a hotel, and the like. However, those skilled in the art will appreciate that the invention may be adapted for other applications as well. The following discussion will describe the invention in relation to a bathroom application.  
         [0035]    As illustrated in FIG. 1, prefabricated housing component  10  comprises a first casting  11 A, a second casting  11 B and an external framework  12 . The castings  11 A and  11 B are formed into a vanity cabinet  13 A, a towel cabinet  13 B, a medicine cabinet  13 C and a light bar  13 D. Other parts of the construction comprise walls  14 A, a ceiling  14 B, and a floor  14 C. The castings  11 A and  11 B are constructed out of fiberglass or composite type materials. The invention may also be practiced with other types of materials such as plastics which may be molded. The fiberglass construction comprises multiple layers of flame retardant resin and glass fibers with a colored gel layer as the finishing layer. A strengthening material, or core material, is included inside the layers of resin and glass fibers. Preferably, this material is a quarter inch layer of wood, and preferably balsa wood. Some portions of the construction include stronger strengthening layers such as ½ inch plywood. Such strengthened portions are used, for example, where drawers or cabinet doors are attached. The two castings  11 A and  11 B are aligned and attached together using an appropriate adhesive.  
         [0036]    The interior of the component is finished by cutting openings in the casting  11 A for the drawers, cabinetry doors, light bar assemblies, and pluming and electrical connections. Conventional doors, drawers, countertops  15 A, sinks, faucets, toilets  15 B, bath tubs  15 C, lights, and electrical outlets  15 D are attached or installed in a conventional manner.  
         [0037]    One aspect of the invention is that once a mold (not shown) is formed or constructed, castings may be made quickly and easily from such mold. The first step in constructing the mold is to construct a female plug (not shown) in the shape of the desired casting such as castings  11 A and  11 B. The plug is virtually identical in shape to the casting  11 A but without the added hardware, faucets and sink. The plug is preferably made of wood and is primed and waxed to a smooth surface. A male mold (not shown) is made from the plug in a conventional manner and the female castings are then created by placing multiple layers of fiberglass surrounding a wood layer on the mold. The casting, such as casting  11 A and  11 B is removed from the mold and inserted inside of the framework  12 . A plurality of support ribs  16 A are secured to the casting  11 A or  11 B prior to placing the casting  11 A or  11 B into the framework  12 . The ribs  16 A are secured to a plurality of studs  16 B of the framework  12 .  
         [0038]    The electrical and plumbing is completed on the component  10  in the factory and is inspected to meet the required building codes. The plumbing and electrical are of a conventional nature, however, a preferred embodiment includes utilizing electrical harnesses and systems that are configured to minimize the number of electrical and plumbing connections required to be made at the construction site.  
         [0039]    Other aspects of the invention include curved or sculptured portions of the castings  11 . Because of the manufacturing technique used, atypical shapes may be introduced into the castings. For example, rounded corners  17  may be used extensively. Other portions may also be curved or contoured surfaces, including cabinetry, walls, floors, and ceilings to provide an appealing, innovative and upscale appearance. The atypical shapes may also be used to provide improved utility such as improved ergonomics, more usable storage and safety features  
         [0040]    [0040]FIG. 2 is a front view of the finished cabinetry of FIG. 1. Shown in FIG. 2 are the lights  21 , electrical outlets  15 D, electrical switches  22 , medicine cabinet mirror doors  23 , towel holders  24 , drawers  25  and cabinet doors  26 . The medicine cabinet  13 C and the towel cabinet  13 B are typically each provided with shelves  27 . To provide shelves  27  and to provide an aesthetically pleasing and useful interior, an insert is provided which is secured into the interior of the medicine cabinet  13 C and the towel cabinet  13 B.  
         [0041]    [0041]FIG. 3 illustrates a cutaway top view of the castings  11 A and  11 B. Shown in the figure is the vanity top  31 , sink  32  and faucets  33 . A pair of alignment pins  34  are shown along a seam  35  located between the castings  11 A and  11 B. Alignment pins  34 , or other alignment devices, are utilized to keep the edges of the castings  11 A and  11 B aligned with one another while the castings  11 A and  11 B are bonded together. The alignment pins  34  save time and reduce the risk of misalignment or imperfections in alignment.  
         [0042]    As illustrated in FIG. 3, the lips  36  of the cabinetry  13 B and  13 C where a drawer  25  or door  26  are attached are preferably reinforced with a rigid reinforcement material, such as ½ inch plywood and the like. As mentioned above, the castings  11 A and  11 B are preferably reinforced with ¼ inch balsa wood bonded inside at least two layers of fiberglass.  
         [0043]    The apertures for the drawers  25 , the towel cabinet  13 B and the medicine cabinet  13 C are cut from the original casting  11 A. The mold if formed to create recessed portions in the casting  11 A so that it is readily apparent where the cuts are to be made. FIGS. 4 and 5 illustrate a cutout line  51  and a preferred water resistant joint  40  for use with an insert  41 , such as the drawers  25  and the cabinets  13 B and  13 C. The casting  11 A is first cut along the edge of the recessed portion  50  as illustrated by the cutout line  51 . The lip  36  of the recessed portion is preferably reinforced with ½ inch plywood, or other suitably functioning reinforcing material as discussed above, for securing and mounting the drawers  25  and doors  23  and  26 . The inserts  41  are sized to fit within the aperture  52  created by cutting along the cutout line  51 . The edges of the insert  41  and the edge of the aperture  52  form the interlocking water resistant joint  40  to securely hold the insert  41  within the aperture  52 . Adhesive is applied to the joint  40  for added strength and water resistance. Inserts  41  are preferably utilized to create the towel cabinet  13 B and the medicine cabinet  13 C.  
         [0044]    Another aspect of the housing component  10  according to the invention is the framework  12  into which the castings  11 A and  11 B are inserted. The framework  12  is constructed according to approved building standards and is preferably constructed of a plurality of studs  12 B, such as 2×4&#39;s and the like. Because the framework  12  is assembled at the factory, it reduces the framing required to be done at the construction site and saves time and money. In a preferred embodiment, the housing component  10  is shipped on a plurality of castors (not shown), thereby allowing the builder to merely lower the completed component to the correct floor within the building, roll the component  10  to the desired location, and secure the component  10  to the associated sub-floor.  
         [0045]    In assembly, the castings  11 A and  11 B are aligned with the alignment pins  34  and secured within the support ribs  16 . The support ribs  16  are bonded to the exterior of the castings  11 A and  11 B and are preferably made of furring strips (e.g., wood strips) of approximately 1 inch by 3 inches.  
         [0046]    The framework  12  is constructed such that a sidewall  12 C is separated from the framework  12  until the castings  11 A and  11 B are inserted into a framework aperture  12 C. Once the castings  11 A and  11 B are in place, the sidewall  12 A is attached to the balance of the framework  12 .  
         [0047]    The castings  11 A and  11 B are then secured to the framework  12  via a plurality of metal brackets  71  (FIG. 8), as shown in FIG. 7. The brackets  71  are L-shaped brackets with oval apertures  71 A extending therethrough to provide for adjustment as the nail or screws secure the brackets  71  to the studs  12 B. Each bracket  71  attaches to both the rib  16  and the stud  12 B. The oval apertures  71 A in the bracket  71  provide adjustment as needed. By using the technique of adjustably securing the castings  11 A and  11 B to the framework  12 , the castings  11 A and  11 B are able to be assembled to the framework  12  while the castings  11 A and  11 B complete the curing process. This design allows for higher throughput by reducing the cycle time required to create each casting  11 A and  11 B. Preferably, using the adjustable technique, permits the castings  11 A and  11 B to be removed from the mold in approximately ½ the time required to attain a fully cured casting. In other words, the productively of each mold is doubled.  
         [0048]    In assembly, alignment pins  34  are located about the circumference of the castings  11 A and  11 B. However, once the castings  11 A and  11 B are adhesively bonded, the alignment pins  34  located near the floor  14 C are ground off or cut off to provide a level floor surface.  
         [0049]    For greater strength, the studs  12 B of framework  12  are then “glassed” i.e., bonded with the composite material  72 , to the exterior of the castings  11 A and  11 B. The bond  72  extends along the entire length of studs  12 B. This construction makes the overall component  10  very strong. The strength of the completed component  10  is contemplated to make it the strongest room of a construction. Therefore, it may also provide improved safety from storms, earthquakes, or similar dangerous conditions. It is also unlikely to be damaged or cracked during shipment to the construction site.  
         [0050]    As illustrated in FIG. 9, the insert  41  of the medicine cabinet  13  includes adjustable shelving as provided by holes  91 A that support pins  91 B for supporting shelves in a conventional manner. Of course, other types of medicine cabinet units may also be used with the invention. Similar type shelving construction may also be utilized within the vanity cabinet  13 A and the towel cabinet  13 B.  
         [0051]    The floor  14 C of the castings  11 A and  11 B is illustrated in FIG. 10. The alignment pin  34  is no longer need after the castings  11 A and  11 B have bonded together via an adhesive  102  and the alignment pin  34  is typically removed. Those of ordinary skill in the art recognize that various configurations of alignment pins, grooves or ridges may be utilized with the invention. The floor  14 C of the castings  11 A and  11 B is preferably covered with a flooring material  103  that provides the desired color or texture of the builder, and comprise linoleum, tile and the like. The flooring material  103  also covers and hides the seam between the castings  11 A and  11 B.  
         [0052]    Preferably, castings  11 A and  11 B are each constructed of multiple layers of fiber glass  111  and epoxy  113  with a colored layer  112  that provides the finished surface visible to the user. The colored layer  112  is preferably a gel coating. Sandwiched between the layers of the fiber glass  111  and the epoxy  113  is a layer of support material  114 . The support material  114  may be cardboard, corrugated cardboard, wood, or other material that can provide adequate support. It is also desirable if the material provides some stress reduction such that the composite materials can move slightly if stress builds sufficiently. The most preferred support materials are ¼ inch bolsa wood for most surfaces, and ½ inch plywood for high stress areas such as the lips  36  of the apertures  52 , where drawers or doors attach. An alternative embodiment utilized a layer of gas trapped between the multiple layers. FIG. 12 is another illustration of the composite construction where the support material is wood.  
         [0053]    An example of the contoured surfaces and the curves that are readily implemented by the use of the invention is illustrated in FIG. 13, showing a curve  130  from the wall  14 A down to the floor  14 C. The invention can also accommodate formation of a recessed portion  131  appropriate for receiving the flooring material  103 .  
         [0054]    Those skilled in the art understand that there are some limitations to the shapes that can be reasonably fabricated using molds. Accordingly, it is understood that some shapes, such as a bathtub  150  (FIG. 14) are more easily formed as a separate casting and then mounted into the appropriate location in the castings  11 A and  11 B. In the alternative, various other tub/shower units may be purchased and installed in the unit in a conventional manner.  
         [0055]    Another aspect of the present invention is to provide a lower drain pain  170  (FIG. 15) located proximate the bathtub  150 , and adapted to prevent water from leaking pipes associated with the bathtub  150 . It should be noted that while the drain pan  170  is described in relation to bathtub  150 , the drain pan  170  may be utilized with a multitude of plumbing fixtures and applications. In the illustrated example, the drain pan  170  includes a housing member  172  having a peripherally extending attachment flange  174 , and a collar member  175  having a peripherally extending attachment flange  176 . In assembly, the housing member  172  is placed below the floor of the housing component  10  proximate a location of water pipes associated with the bathtub  150 , such as a drain pipe  178 , an over-flow pipe  180 , and the like. The housing member  172  is connected to the floor of the housing component  10  via a plurality of mechanical fasteners and caulk. The collar member  175  is aligned with the housing member  172 , and the flange  176  of the collar member  175  is attached to an upper surface of the floor of the hosing component  10  via a plurality of mechanical fasteners and caulk.  
         [0056]    In another aspect of the invention, a kitchen room  140  (FIG. 16) may be implemented with similar advantages as discussed for the bathroom. Similar to the casting  11 A and  11 B of the bathroom component  9 , castings  141  of the kitchen room  140  are formed and bonded together. Inserts such as cabinets and counters  142  are formed in a similar manner as described above. Locations for accessories such as sinks  143 , ovens  144 , dishwashers  145  and a refrigerator  146  are also provided. The advantages of pre-plumbing and electrical wiring provide savings similar to the bathroom component  9  described above.  
         [0057]    As illustrated in FIGS. 17 and 18, a plurality of trolley assemblies  150  utilized to support the housing component  10  during the installation process. Each trolley assembly  150  includes castor wheel  152  connected to an associated stud  16 B via s support bracket  154  and mounting hardware. Each support bracket includes a mounting portion  156  adapted to connect to the stud  16 B, and a wheel support portion  158  integral with and extending substantially orthogonal to mounting portion  156 . The mounting portion  156  includes a plurality of elongated, longitudinally extending slots  160 , and a plurality of apertures  162 , all of which are adapted to receive mounting hardware such as lugs  164  therein. In assembly, the trolleys  150  are located with respect to the housing component  10  so as to provide clearance between a sub-floor  166  and the housing component  10 , thereby allowing the housing component to be rolled along the sub-floor  166 . The lugs  164  are tightened within the slots  160  to maintain this clearance. Additionally, the lugs  164  may be placed within apertures  162 , thereby preventing the possibility of the lugs  164  sliding within the slots  160  and the housing component  10  touching the sub-floor  166 . Once the housing component  10  is delivered to the proper located within the building, the lugs  164  are removed from within the apertures  162  and the slots  160 , thereby allowing the housing component  10  to rest on the sub-floor  166 .  
         [0058]    It will become apparent to those skilled in the art that various modifications to the preferred embodiment of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims.