HOUSING UNIT SYSTEM AND METHOD OF MANUFACTURE

A housing unit includes a central mast configured to be coupled to a portion of terrain, and upper ring, a lower ring, one or more wall panels, wherein the upper ring, the lower ring, and the one or more wall panels define a living space outer boundary, a plurality of first tensile members each configured to couple the upper ring to the central mast at a first central mast region, wherein the upper ring is configured to be suspended by the plurality of first tensile members below the first central mast region, and a plurality of second tensile members each configured to couple a periphery of the lower ring to a periphery of the upper ring, wherein the lower ring is configured to be suspended by the plurality of second tensile members below the upper ring and above the portion of terrain, wherein the upper ring and the lower ring are coupled to the portion of terrain only at the central mast.

BACKGROUND

Field of the Invention

The field of the invention generally relates to structures with suspended parts supported by masts or tower-like structures, whether individual or arranged together into a community.

SUMMARY OF THE INVENTION

In one embodiment of the present disclosure, a housing unit includes a central mast configured to be coupled to a portion of terrain, an upper ring, a lower ring, one or more wall panels, wherein the upper ring, the lower ring, and the one or more wall panels define a living space outer boundary, a plurality of first tensile members each configured to couple the upper ring to the central mast at a first central mast region, wherein the upper ring is configured to be suspended by the plurality of first tensile members below the first central mast region, and a plurality of second tensile members each configured to couple a periphery of the lower ring to a periphery of the upper ring, wherein the lower ring is configured to be suspended by the plurality of second tensile members below the upper ring and above the portion of terrain, wherein the upper ring and the lower ring are coupled to the portion of terrain only at the central mast.

In another embodiment of the present disclosure, a housing unit includes a central mast configured to be coupled to a portion of terrain, an upper ring, a lower ring, one or more wall panels, wherein the upper ring, the lower ring, and the one or more wall panels define a living space outer boundary, a plurality of first tensile members each configured to couple the upper ring to the central mast at a first central mast region, wherein the upper ring is configured to be suspended by the plurality of first tensile members below the first central mast region, and a plurality of second tensile members each configured to couple a periphery of the lower ring to a periphery of the upper ring, wherein the lower ring is configured to be suspended by the plurality of second tensile members below the upper ring and above the portion of terrain, wherein the only portion of the housing unit extending into the terrain is located at the central mast.

In yet another embodiment of the present disclosure, a housing unit community includes a plurality of housing units each including a central mast configured to be coupled to a portion of terrain, a polygonal upper ring, a polygonal lower ring, one or more wall panels, wherein the upper ring, the lower ring, and the one or more wall panels define a living space outer boundary, a plurality of first tensile members each configured to couple the upper ring to the central mast at a first central mast region, wherein the upper ring is configured to be suspended by the plurality of first tensile members below the first central mast region, a plurality of second tensile members each configured to couple a periphery of the lower ring to a periphery of the upper ring, wherein the lower ring is configured to be suspended by the plurality of second tensile members below the upper ring and above the portion of terrain, wherein the upper ring and the lower ring are coupled to the portion of terrain only at the central mast, wherein each of the plurality of housing units includes a plurality of sides, and wherein one side of each of the plurality of housing units is adjacent and parallel to another side of another of the plurality of housing units.

DETAILED DESCRIPTION

The disclosure generally relates to modular housing for use as a single unit, or as part of an arranged community of individual units. Each single unit comprises at least partially suspended structure. The unit or community of units provide several features, including at least some of: sustainability, modularity, affordability, resiliency. A SMART™ Unit, or S.M.A.R.T.™ Unit, is a name or phrase for these units, built by initials of the following descriptive words, while not including any one or more of them: Sustainable, Modular, Affordable, Resilient, and Tensile.

The United States confronts a rise in the lack of unaffordable housing and, as a result, an increase in homelessness. This is also true for many other first-world and non-first-world countries. As of 2024, 777,000 individuals have been determined to be living on the streets of the U.S., according to the U.S. Department of Housing and Urban Development. Despite substantial government spending on temporary solutions, such as emergency shelters and services, the issue persists. The spending can exceed $35,000 per homeless person per year in major cities, according to the National Alliance to End Homelessness. “The Gap: A Shortage of Affordable Homes,” a report published March 2023 by Aurand et al., conservatively estimated the shortage of rental homes affordable and available to extremely low-income households to be close to 7.8 million.

Homelessness in the United States is not solely the result of the lack of affordable housing but is also driven by a complex interplay of factors, including financial instability, unemployment, physical disabilities, mental health challenges, substance abuse, and systemic barriers to support services. The embodiments of modular housing for use as a single unit, or as part of an arranged community of individual units address a two-fold solution, addressing both the shortage of homes and the complex collection of economic and social issues. This includes, but is not limited to, providing scalable housing to meet the growing demand and enabling the creation of a rehabilitative environment designed to support the mental, physical, and social well-being of its inhabitants, thus helping them transition toward stability and self-sufficiency.

In a first embodiment, a (S.M.A.R.T.) housing unit comprises a hexagonal design based on six substantially rectangular wall panels, six triangular roof panels, and six triangular floor panels. In some embodiments, one or more of the panels can be replaced by an alternate panel having an opening, for a door, and/or for a window. In some embodiments, the six wall panels comprise five wall panels with a window and one wall panel with a door. In some embodiments, a floor panel includes an opening for a door, to couple to a stairway and/or ramp. In some embodiments, a roof panel includes an opening for a door, to couple to a walkway, a stairway and/or a ramp. The wall, roof, and floor panels are each secured to an upper hexagonal ring and/or a lower hexagonal ring by a series of tensile wires, or multi-filar cables. All of these components are connected to a central, vertically-extending mast. The hexagonal shape provides structural efficiency and modularity. Multiple hexagonal units can be interconnected without complication, while optimizing space and minimizing material use and material complexity. This geometric configuration evenly distributes stresses and supports the tensile construction.

Each of the components (wall panels, roof panels, floor panels) are prefabricated, and allow for quick assembly, thus enhancing the scalability and adaptability of different multi-unit set-ups. The hexagonal structure facilitates efficient clustering of units into communities with a generally circular or polygonal form. These forms enable the creation of shared courtyards that foster social engagement and stability among residents while enabling the efficient distribution of utilities and infrastructure.

FIGS. 1-2 illustrate a housing unit 100 comprising an upper hexagonal ring 101, a lower hexagonal ring 102, and a vertically-extending central mast 103. The upper hexagonal ring 101 and the lower hexagonal ring 102 are each suspended from the central mast 103 by a series of first tensile cables 104 and a series of second tensile cables 105. In some embodiments, the upper hexagonal ring 101 is connected via each of the first tensile cables 104 to a first portion 106 of the central mast 103, and is configured to hang below the first portion 106. The lower hexagonal ring 102 is connected via each of the second tensile cables 105 to the upper hexagonal ring 101, and is configured to hang below the upper hexagonal ring 101. In some embodiments, the series of tensile cables 104 comprises twelve cables 104. In some embodiments, the series of tensile cables 105 comprises twelve cables 105.

The upper hexagonal ring 101 comprises six straight horizontal beams 107a-f connected to each other at angles A of 120°. Turning to FIG. 3, each beam 107 has a length L of between about 7 feet and about 18 feet, or about 9 feet and about 15 feet, or about 12 feet. Each beam has an end bevel angle B of 30°. Thus. two adjacent ends, e.g., first end 108 of a first beam 107b and second end 109 of a second beam 107a form a 120° angle between the beams 107a, 107b, when a first end surface 110 is flush or substantially adjacent to a second end surface 111. The lower hexagonal ring 102 comprises six straight horizontal beams 113a-f connected to each other at angles C of 120°. Each of the beams 113 can also follow the form and sizing of the beam 107 shown in FIG. 3. The beams 107, 113 comprise hollow extrusions of aluminum or steel, or can comprise I-beams. In some embodiments, the hollow extrusions can allow one or more of the beams 107a-f, 113a-f to serve as utility conduits (power, water, gas, sewage). FIGS. 9A and 9B illustrate an assembly process of either ring 101, 102.

Six roof panels 118a-f are assembled above the upper hexagonal ring 101. Each of the roof panels 118 comprises at least an external plate 119 (e.g., outer sheet) having a general triangular shape, with a base side 120, first leg side 121a and second leg side 121b. The two leg sides 121a, 121b have the same length. The roof panel 118 further includes a cut-away section 122 comprising an arc concave face 123 that is configured to fit around a 60° circumferential portion of the central mast 103, in some embodiments, just above the first portion 106. In some embodiments, the end of the roof panel 118 having the cut-away section 122 is angled 25° to 65° above the horizontal, or about 45°, or about 30° above the horizontal. The roof panel 118 further includes an inner sheet 124. As shown in FIG. 2, in order to provide a close fit in the structure of the housing unit 100 when the roof panel 118 is in its angled configuration, the inner sheet 124 has a similar, but smaller, scaled size in relation to the external plate 119. Thus, sides 121a of each external plate 119 are adjacent to or touching the sides 121b of each adjacent external plate 119. Furthermore, sides 125a of each inner sheet 124 are adjacent to or touching sides 125b of each adjacent inner sheet 124. An annular cap 137 having an inner hole 138 and an outer dimension 139, is secured over the central mast 103, and helps to hold or lock the apices of the roof panels 118a-f in place around the central mast 103. Below the annular cap 137 (e.g. on the mast 103), or attached to the bottom of the annular cap 137, a circular light-emitting diode (LED) ring light can be connected. The LED is configured to provide overhead lighting within the living space.

One or more of the roof panels 118a-f can comprise a bracket 141, or containment portion, comprising a lower undercut 142 or pocket, that is configured to hold an individual solar panel 143. The undercut 142 supports the solar panel 143 and provides the required electrical connections and mechanical connections (snaps, friction fit, screw attachment, etc.). The wires, batteries, charge controller, inverter, and other electronics can be stored within an attic storage area (above the upper ring 101 and below the roof panels 118). Access doors can be provided in one or more roof panels 118 to provide access to the attic area. The electronics of the solar panels 143 can further be connected through an opening provided in the central mast 103. The solar panel in some embodiments is a lateral (long) side of about one meter in length. The central mast 103 can comprise a central lumen or passageway 144, to allow any electrical wires and/or plumbing tubes to pass therethrough, to conceal them and direct them. For example, electrical wires for the solar panel, power, and lighting, can pass through an upper portion of the passageway 144, e.g., above the lower hexagonal ring 102. Sewage and wastewater can be conveyed, with the help of gravity, through a lower portion of the passageway 144, e.g., below the lower hexagonal ring. Fresh hot and cold water can be supplied through either the upper or lower portions of the passageway 144. In other embodiments, the central mast 103 comprises a solid post. The central mast 103 is shown as a cylinder having a circular cross-section of a single diameter throughout its length. In other embodiments, the circular cross-section can vary, for example, flaring from a larger diameter below, to a smaller diameter above. In other embodiments, the central mast 103 has a hexagonal cross-section shape, whether hollow, or solid.

Six wall panels 126a-f are assembled substantially between the upper hexagonal ring 101 and the lower hexagonal ring 102. Each of the wall panels 126 comprises at least an external plate 127 (e.g., outer sheet) having a general rectangular shape, with a lower side 128, upper side 129, left side 130, and right side 131. The wall panels 126a-f are configured to fit against at least a portion of a particular beam 107 and at least a portion of a particular beam 113, below the beam 107. The wall panel 126 further includes an inner sheet 132. As shown in FIG. 2, in order to provide a close fit internally and externally in the structure of the housing unit 100, the inner sheet 132 has a similar, but smaller, horizontal width in relation to a horizontal width of the external plate 127. Thus, sides 133a of each external plate 127 are adjacent to or touching the sides 133b of each adjacent external plate 127. Furthermore, sides 134a of each inner sheet 132 are adjacent to or touching sides 134b of each adjacent inner sheet 132. One or more of the wall panels 126a-f can include an opening 135 configured for placement of a window 136 (FIG. 1). The roof panels 118 and wall panels 126 can be configured to have different external dimensions and internal dimensions. The external dimensions (width, height, etc.) can be a certain percent larger than the related internal dimensions, such that fit with the other components, such as the rings 101, 102, is tight or flush. Though the structure is not necessarily circular, the ratio π predicts the change in widths depending upon where the tangent line is located on the radius. The difference in the wall panel heights, external and internal, can vary based on a differential that is generally the same as the height (thickness) of each ring 101, 102.

Six floor panels 112 (only one shown in FIG. 2) are assembled above the lower hexagonal ring 102. Each of the floor panels 112 comprises a general triangular shape, with a base side 114, first leg side 115a and second leg side 115b. The floor panel 112 further includes a cut-away section 116 comprising a 60° arc concave face 117 that is configured to fit around a 60° circumferential portion of the central mast 103. The electrical, water, and waste (conduits), can alternatively be passed through any one or more of the roof panels 118, wall panels 126, or floor panels 112. The floor panels 112 can be configured to have lateral flanges such that adjacent floor panels 112 are installable in an interlocking pattern with the long edges resting on the adjacent floor panel 112. Furthermore, flange-like structures, such as the recessed interiors 181, 182 described in relation to FIG. 18, are configured for the floor panels 112 to rest thereon, as will be described in more detail below. A similar overlapping construction is also possible for the roof panels 118. Each of the floor panels can be configured to provide radiant heating.

The central mast 103 of the housing unit 100 comprises a lower end 145 that is configured to be coupled to a portion of terrain 146 (ground, soil, sand, dirt, grass, etc.), wherein the lower extreme 147 of the lower hexagonal ring 102 clears the portion of terrain 146, and does not contact any portion of the terrain 146. All of the housing unit 100, except for the central mast 103 is thus suspended from the central mast 103. No direct attachment of the lower hexagonal ring 102 to the portion of the terrain 146 is required. A space, or elevation h, between the lower extreme 147 of the lower hexagonal ring 102 and the portion of the terrain 146 is in some embodiments between about 0.75 foot (0.23 meter) and about 15 feet (4.57 meters), or between about one foot (0.30 meter) and about 3.3 feet (1.0 meter). This assumes that the lower extreme 147 is the lowest portion of the housing unit 100 (other than the portion of the central mast 103 that extends below it), In other embodiments, the can be additional attachments to the bottom of the lower hexagonal ring 102, with the clearance also adjusted to be between about 0.75 foot and about 15 feet, or between about one foot and 3.3 feet. The housing unit 100 can be constructed on terrain that has a grade of 10.5% or less (e.g., approximately a 6° slope or less). A common distance between the rings 101, 102 can be about nine feet, or between about eight feet and about twelve feet. The distance between the upper ring 101 and the top of the structure can be about eight feet, or between about five feet and about twelve feet. In some embodiments, a 27 foot tall central mast 103 is utilized, with about nine feet intended for placement below ground level and about eighteen feet intended to extend above ground level.

By controlling the length of the central mast 103 and/or the lower end 145 of the central mast 103 that is placed below ground, the desired elevation h of the lower extreme 147 of the lower hexagonal ring 102 above the portion of terrain 146. In some embodiments, the lower end 145 of the central mast 103 comprises a helical pier, and is configured to be screwed into the soil until a desirable load capacity has been achieved. In some embodiments, the soil is dug with an auger or other tool, and a sono tube is used for controlling the amount and shape of poured cement, into which the lower end 145 of the central mast 103 is embedded, as the concrete solidifies. The lower end 145 can include one or more radial projections extending therefrom, which, when bonded within the hardened concrete, provides rotational resistance and stability. Thus, the central mast 103 is statically coupled to the concrete. The lower end 145 can also comprise a textured cylindrical or other shaped surface, to also provide rotational resistance and stability. See also FIGS. 11 and 23.

FIG. 18 illustrates the rings 101, 102, tensile wires 104, 105, and central mast 103 of an alternative embodiment framework 180 for a housing unit 100. Each of the rings 101, 102 can comprise six beams 107 connected into a hexagonal frame shape. Each of the rings 101, 102 includes a recessed interior 181, 182, respectively, extending around the upper interior of the ring 101, 102. The recesses 181, 182 provide a location for connectors 183, 184 for the tensile wires 101, 102 to be coupled, respectively. The recesses 181, 182 also provide a substantial flat area for the overlay of outer edges of the roof panels 118 or the wall panels 126. In alternative embodiments, the tensile wires 104 and tensile wires 105 can together comprise a single wire that is connected to the upper portion of the mast 103, secured to the connectors 183 and inserted through apertures in the upper ring 101, and then secured to the connectors 184.

In the embodiments of FIGS. 1-2, 18, and 22-23, the tensile wires 104 (cables) are configured to be internal and fully covered over by the roof panels 118. Thus, the tensile wires 104 are not visible in FIG. 1. In an alternative embodiment of FIG. 11, the tensile wires 104 are configured to be external to the roof panels 118. In still another embodiment, as shown in FIG. 23, the tensile wires 104 can be configured to extend between two different layers (e.g., inner and outer) of the roof panels 118, in a somewhat similar manner as that shown in FIG. 12 in relation to wall portions. These multiple embodiments of wire location (internal, external, extending within) are also possible for the tensile wires 105 and the wall panels 126.

FIG. 4 illustrates a cross-section of a roof panel 150. The roof panel 150 comprises a composite structure having layers 153, 155, 156, 157, 158. An exterior metallic layer 153 provides an exterior surface 154 to the outdoor ambient environment 151. The metallic layer 153 can comprise steel, or aluminum, or painted aluminum, or anodized aluminum. Adhered within the metallic layer 153 is a layer of recycled high-density polyethylene (HDPE) film 155. Adjacent to this layer is a substantially thick layer of insulation 156, comprising an insulative material such as cellulose. An internal ceiling panel 158, having an interior surface 159 facing the interior 152 environment of the living space of the housing unit 100, is secured to the insulation 156 with ceiling batten framing 157. In alternative embodiments one or more air gaps/vapor barriers, can be provided to add further insulation, for example on one or both sides of the insulation 156. The composite structure of the roof panel 150 thus provides protection from sunlight and ultraviolet (UV) radiation, thermal insulation and temperature stabilization, protection from humidity and weather, protection from pests, and physical durability.

FIG. 5 illustrates a cross-section of a floor panel 160. The floor panel 160 comprises a composite structure having layers 161, 163, 164, 165. An exterior metallic layer 161 provides an exterior surface 162 to the outdoor ambient environment 151. The metallic layer 161 can comprise steel, or aluminum, or painted aluminum, or anodized aluminum. Adhered within the metallic layer 161 is a substantially thick layer of insulation 163, comprising an insulative material such as cellulose. An internal floor panel 165, having an interior surface 166 facing the interior 152 environment of the living space of the housing unit 100, is secured to the insulation 163 by a oriented strand board (OSB) subfloor 164. The internal floor panel 165 can comprise cork or corrugated paper. In alternative embodiments one or more air gaps can be provided to add further insulation, for example on one or both sides of the insulation 163. The composite structure of the floor panel 160 thus provides protection from sunlight and ultraviolet (UV) radiation, thermal insulation and temperature stabilization, protection from humidity and weather, protection from pests, including termites via the OSB, and physical durability.

FIG. 6 illustrates a cross-section of a wall panel 170. The wall panel 170 comprises a composite structure having layers 171, 173, 174, 175, 176. An exterior fiber cement panel 171 provides an exterior surface 172 to the outdoor ambient environment 151. The exterior fiber cement panel 171 can be painted or decorated to enhance aesthetics. Adhered within the fiber cement panel 171 is a layer of recycled high-density polyethylene (HDPE) film 173, or low-density polyethylene (LDPE) film. Adjacent to this layer is a substantially thick layer of insulation 174, comprising an insulative material such as cellulose. An internal recycled wood fiber panel 176, having an interior surface 177 facing the interior 152 environment of the living space of the housing unit 100, is secured to the insulation 174 with light batten framing 175. In alternative embodiments one or more air gaps can be provided to add further insulation, for example on one or both sides of the insulation 174. The composite structure of the wall panel 170 thus provides protection from sunlight and ultraviolet (UV) radiation, thermal insulation and temperature stabilization. The panel 176 comprises an inner substantially impermeable, substantially fire-retardant sheet. In some embodiments, the panel 176 can comprise a recycled woof fiber panel.

Each of the panels 150, 160, 170 can vary from five inches in thickness to ten inches in thickness, or between six inches and eight inches. Any of the external layers 153, 161, 171 and/or internal layers 158, 165, 176 can be treated and/or coated to increase fire-retardant and/or water-resistant characteristics. In some embodiments, an additional internal layer comprising polymeric plastic or resin can be applied to make the composite more weatherproof, and durable.

FIG. 7 illustrates a T-shaped bracket 200. FIG. 8 illustrates the T-shaped bracket 200 in an assembled state coupling a wall panel 201 and a floor panel 202. The T-shaped bracket 200 comprises a high-strength metal, and comprises an upwardly-extending projection 203, and inwardly-extending projection 204, and a downwardly-extending projection 205. The T-shaped bracket 200 has a “T” cross-section. A plurality of T-shaped brackets 200 are configured to be secured to the lower hexagonal ring 102. For example, there can be two, three, four, five, six, or more T-shaped brackets 200 per each of the six sides of the housing unit 100. The upwardly-extending projection 203 comprises a substantially vertical planar face 206, and has two cylindrical through holes 207, 208 passing therethrough. The inwardly-extending projection 204 comprises a substantially horizontal planar face 209, and has two cylindrical through holes 210, 211 passing therethrough. The downwardly-extending projection 205 comprises a substantially vertical planar face 212, and is reinforced by an angular connection plate 213 joining the downwardly-extending projection 205 to the inwardly-extending projection 204. The T-shaped bracket 200 can be formed by metal extrusion, CNC machining, or other additive or subtractive processes.

FIG. 8 illustrates a first bolt 214 passing through a first hole 215 of the wall panel 201 and through a hole 207 of the T-shaped bracket 200. The bolt 214 is tightened with a nut 216 to force a wall face 217 against the substantially vertical planar face 206, to maintain the wall panel 201 secure, and vertical. FIG. 8 also illustrates a second bolt 218 passing through a first hole 219 of the floor panel 202 and through a hole 210 of the T-shaped bracket 200. The bolt 218 is tightened with a nut 220 to force a floor face 221 against the substantially horizontal planar face 209, to maintain the floor panel 202 secure, and horizontal. The plurality of T-shaped brackets 200 aid in maintaining the flooring (e.g., a plurality of floor panels 202) substantially level. In some embodiments, a second type of bracket can be used that connects the roof panels to the upper hexagonal ring 101. In these brackets, the upwardly-extending projection 203 can be replaced by an angled projection that is angled at the desired orientation of each of the roof panels.

In an alternative embodiment, the T-shaped bracket 200 is replaced by an L-shaped bracket, having only the upwardly-extending projection 203 and the inwardly-extending projection 204. In another alternative, shown in FIG. 18, the bracket 200 is not a separate component, but is instead a feature (recesses 181, 182) that is integral to the frame, and specifically to the upper ring 101 and/or the lower ring 102. The detail of the T-shaped bracket (planar faces 206, 209, holes 207, 208, 210, 211) is included in the configuration of the rings 101, 102. Though the upper ring 101 is shown in FIG. 18 with a substantially 90° angulation between the upwardly-extending projection 190 and the inwardly-extending projection 191, an acute angle can exist between them, such that the upwardly-extending projection, also has at least some inward extension. For example, 60°, 45°, or 30°, or 20° to 70°, or 25° to 65° from the horizontal plane.

FIG. 25 illustrates another T-shaped bracket 550, or alternatively, a feature (recesses 181, 182) that is integral to the frame, and specifically to the upper ring 101 and/or the lower ring 102. The floor panel 160 and the wall panel 170 includes the composite layered structure as described with FIGS. 5 and 6, respectively. However, the floor panel 160 includes a step 551 or recess configured to fit the upwardly-extending projection 552 and the downwardly-extending projection 553 of the T-shaped bracket. The floor panel 160 and the wall panel 170 can be coupled with screws or other fasteners, or can be bonded with flexible adhesives, such as urethane adhesive, or adhesive tape.

FIG. 11 illustrates a hexagonal housing unit 230 comprising a central mast 231 having an upper portion 232 and a lower portion 233. The lower portion 233 is shown embedded in earth 234, and surrounded at its lowest portion 237 by solidified concrete 272 within an augered hole 236. In the embodiment of FIG. 23, approximately one-third of the length of the central mast 231 is configured to be placed under the earth 234, or about one-fifth to one-half of the length. The depth DT to the top of the solidified concrete 272 in FIG. 11 is not necessarily shown to scale. In some embodiments, this depth DT is significantly more than the total height HC of the solidified concrete 272. The upper portion 232 of the central mast 231 includes eyelets 238, 239 for attaching to a first end 240 of the first tensile cables 104. The upper hexagonal ring 101 is connected to brackets 241 that attach to a second end 242 of the first tensile cables 104. The upper hexagonal ring 101 thereby hangs from the upper portion 232 of the central mast 231. The bracket 241 connects to roof panels 118 and wall panels 126 in a similar manner to bracket 235 of FIGS. 7-8, and is connected to an additional coupler 243 having upper eyelets 244 and lower eyelets 245.

The lower hexagonal ring 102 hangs via second tensile cables 105. A first end 246 of the second tensile cable 105 connects to the lower eyelet 245 of the coupler 243, and a second end 247 connects to an eyelet 248 of a coupler 249 that is connected to a bracket 235. The brackets 235, couplers 243, and lower hexagonal ring 102 of FIG. 11 hang about the surface of the terrain. The only necessary connection to the terrain/soil is via the central mast 231. This minimal connection requires only a very small area of the terrain that needs preparation. Furthermore, the hanging nature of the structure can provide a dwelling that does not have a excessive amount of internal stresses, and is not over-constrained at key structural portions. Thus, during seismic events, the housing unit 230 is able to avoid catastrophic failure, and can prove to be quite durable. In alternative embodiments, additional connections between the lower hexagonal ring 102 and/or the upper hexagonal ring 101 are possible.

Assuming that the central mast 231 extends along a vertical Z-axis, further stability can be added along the X-axis and/or Y-axis (Cartesian coordinates), or along the R-axis (cylindrical coordinates). FIG. 10 illustrates an alternative ring 250 comprising an outer hexagonal perimeter of beams 251, an internal ring 252 configured to couple to the central mast 231, and six spoke-like beams 253a-f that radially connect the internal ring 252 and the perimeter of beams 251.

Further stability, resilience, and robustness can be added to the structure of the hexagonal housing unit 230 via circular plates 254, 255, 256. The plates 254, 255, 256 serve as connecting points or joints within the structure, and facilitate modular assembly. Each plate is configured to be connected to the central mast 231 at a different longitudinal location along the central mast 231. The upper circular plate 254 is configured to be secured around the upper portion 232 of the central mast 231, and to interface with the arc concave face 123 of the roof panel 118, or with another portion at the apex of the roof panel 118. The roof panel also possesses a flat surface at its upper apex that is parallel to the horizontal and intended to engage the central mast 231 in a flush manner. This is somewhat equivalent to the two staggered cut-away sections 122 comprising an arc concave face 123 shown in FIG. 2. The flush cut simply outlines the circumference of the mast, while the flat top part of the roof panel rests on the extrusion plate 254. The intermediate circular plate 255 is configured to be secured around an intermediate portion 257 of the central mast 231. It is also configured to directly engage the internal ring 252 of the alternative ring 250. The intermediate circular plate 255 can also indirectly be coupled to the upper hexagonal ring 101, via additional components (e.g., radially extending tension wires). The lower circular plate 256 is configured to be secured at or near the lower portion 233 of the central mast 231. It is also configured to directly engage the internal ring 252 of the alternative ring 250. The lower circular plate 256 can also indirectly couple to the lower hexagonal ring 102, via additional components (e.g., radially extending tension wires). It can also be coupled to the floor panels 112. The circular plates 254, 255, 256 can be coupled to the assembly without being directly coupled to the central mast 231. This can avoid an over-constrained structure.

FIGS. 19-20 illustrate the attachment of a plate 255 to the central mast 231. In some embodiments, the place can comprise a first semi-circular plate section 255a and a second semi-circular plate section 255b, each having an internal semi-cylindrical concave contour 273a, 273b, respectively, configured to engage an outer cylindrical surface of the cylindrical mast 231. The two sections 255a, 225b can each include semi-circular flanges 275a, 275b having transverse holes (not shown), and configured to be attached to each other via screws passing through holes, and in the process being securingly tightened to the central mast 231. Each section 255a can optionally include a plurality of through holes 274 through which tension wire can pass, for further securement. In other embodiments, no tension wires are used along the central mast 231, and thus, the holes 274 are not utilized. A decoupling collar 283 is carried above the plate 255. Six spoke-like beams 276a-f extend from the decoupling collar 283, and comprise outer ends 277 configured to couple to the ring 101. The decoupling collar 283, analogous to the internal ring 252 of FIG. 10, rests on top of the plate 255 while maintaining zero to minimal contact with the central mast 231, because of a two to three cm gap shown. This is shown in more detail in FIG. 20. In some embodiments, a lower flange of the lower ring 256 can project downward and extend into the ground/terrain/soil with the central mast 231, as a composite central mast 231 system.

Using the intermediate circular plate 255 as an example, any of the plates 254, 255, 256 can comprise an upper annular plate structure 258, and a plurality of angled beams 259. In some embodiments, the angled beams 259 can be replaced with a conical structure, whose lower end connects to the central mast 231 and whose upper end connects to the upper annular plate 258.

FIG. 22 illustrates another alternative embodiment framework 185 for a housing unit 100. The framework 185 utilizes the alternative ring 250 of FIG. 10 and the plate 255 of FIGS. 19-20. The plate 256 is also similar to the plate 255 of FIGS. 19-20.

FIG. 12 illustrates an alternative cross-section of a wall panel 260. An outer cladding 261 can comprise a sheet of high-strength metal, such as cast alloy steel. An air gap 262 insulates between the cladding 261 and a sheet 263 that provides a barrier. An insulative layer comprises a sheet 264 of a material, such as carbon fiber. Interior siding 265 encloses the other materials to provide a safe internal environment in the living space. An upper bracket 266 and a lower bracket 267 provide connectors 268, 269, respectively, to which tensile wire 270 is attached. In this composite wall panel 260 design, the tensile connections are hidden within the interior of the wall, and not visible.

FIG. 13 illustrates a hexagonal a housing unit 100 that includes an additional water harvesting system 300. The water harvesting system comprises a single, substantially vertical tube 301 comprising an internal lumen 302 or passageway that extends its length, and is closed off at the lower end 303 via a blockage 304. The blockage can comprise concrete or a bonded cylindrical structure. The lumen 302 is configured to be filled to the top end 305 of the tube 301. In some embodiments, one or more drainage holes 306 can be located below the top end 305, to define the top end of a water column that can fill the lumen 302. An angled gutter 307 is carried by either the roof panel 118b and/or by the upper hexagonal ring 101. The gutter 307 can be attached by cement, adhesive, or other building materials, or can be mechanically fitted in place. The gutter 307 comprises a concave trough 308 having a first end 309 and a second end 310. The first end 309 is at least slightly higher in elevation than the second end 310. The gutter 307 tapers in width to the second end 310 as does the trough 308, forming an apex 311 at the second end 310 that is configured to pour rainwater into the top opening 312 of the tube 301. The trough 308 includes an outward-facing longitudinal barrier edge 313 and an inward-facing edge 314. The inward-facing edge 314 is configured to smoothly transition to the slope of the roof panel 118b, such that rainwater 316 landing on the roof panel 118b is pulled down by gravity along the upper surface 315 of the roof panel 118b, moves over the inward-facing edge 314 and into the trough 308. Gravity then moves the rainwater 316 in the trough 308 toward the apex 311 and delivers it into the lumen 302 of the tube 301. The tube 301 is shown in FIG. 13 to be located just outside an apex of the hexagonal shape of the housing unit 100. However, in other embodiment, the tubes 301 can also be located at any part along one or more wall panel 126.

The captured rainwater 316 can substantially fill the lumen 302 of the tube 301, and is protected against evaporation, because of the comparatively small surface area of the top opening 312, which is the only interface of the captured water with the ambient environment. Alternatively, a small roof structure (not shown) can be carried above the opening 312, without blocking it, to significantly protect against hard materials (plant material, animal feces, etc.) from entering. In other embodiments, a layer of screen or filter material can be placed above some or most of the opening 312, to further ensure cleanliness of the water. Though a single tube 301 and single gutter 307 are shown in FIG. 13, in some embodiments, six of each can be utilized, with a tube 301 at each apex, and a gutter 307 extending along an adjacent roof panel 118. In other embodiments, three of each can be utilized, with a tube 301 at every other apex and a gutter 307 at every other roof panel 118.

An alternative water harvesting system 300′ is illustrated in FIG. 14, and comprises an additional gutter 317 having a trough 318. The first end 319 is at least slightly higher in elevation than the second end 320. The gutter 317 tapers in width to the second end 320 as does the trough 318, forming an apex 321 at the second end 320 that is configured to pour rainwater into the tough 308 of the first gutter 307 near its first end 309. The trough 318 includes an outward-facing longitudinal barrier edge 323 and an inward-facing edge 324. The inward-facing edge 324 is configured to smoothly transition to the slope of the roof panel 118a, such that rainwater 316 landing on the roof panel 118a is pulled down by gravity along the upper surface 325 of the roof panel 118a, moves over the inward-facing edge 324 and into the trough 318. Gravity then moves the rainwater 316 in the trough 318 toward the apex 321 and delivers it into the trough 308, for its subsequent passage therethrough, and into the top opening 312 in the tube 301. The gutter 307 and/or the gutter 317 can span substantially the entire width of a roof panel 118, or alternatively can partially span a roof panel 118.

The water harvesting system 300, 300′ can include a faucet 326 that hydraulically communicates with the lumen 302, and allows the resident to directly access the water, via an on/off valve 327, which can be operated by a faucet handle or dial, or similar device. The water harvesting system 300, 300′ can also supply water to lavatory or kitchen fixtures 271 (FIG. 11) via a tube 328 that connects between the fixtures 271 and the lumen 302.

In some embodiments, the water harvesting system 300, 300′ can comprise a cistern 322 (FIG. 14), wherein the bottom of the tube 301 does not have a blockage 304, and instead opens into the cistern 322. Multiple tubes 301 can connect in this matter to one cistern 322. Either way, the cistern 322 allows for the storage and repurposing of a larger amount of water. The tubes 301 and the cistern 322 have the capability to store water for a variety of purposes. Non-potable uses can further include irrigation in local gardens or groves, or flushing of toilets. This reduces the water demand from other local resources. In turn, the housing unit 100 is less dependent on municipal water supplies, reducing the environmental impact associated with traditional water sourcing and treatment.

Turning to FIGS. 26-27, in another embodiment, the individual roof panels 118a-f are replaced with paired downwardly-sloping roof panels 518a, 518b. In addition, one panel 518a slopes inwardly from right to left, and the other panel 518b slopes inwardly from left to right, thus creating a V-cross-section comprising a trough 519 having an longitudinal centerline 520. The trough 519 has an apex 521 at the apex of the hexagonal shape, and three tubes 301a-c are placed adjacently to the three apices 521, such that the drainage of the roof panel pairs 518a, 518b, is guided into the lumens 302 of the tubes 301. Rainwater 316 is guided down the trough 519 in the direction of the arrow in FIG. 27, and into the lumens 302 of the tubes 301. The tubes 301 can have any of the structure and functionality as the tubes 301 of FIG. 13 or 14, including the ability to couple to the cistern 322.

FIGS. 15-16 illustrate a community 400 that has been constructed from five of the housing units 100a-e. Arrangement of the housing units 100 into clusters, such as the community 400, can enhance structural durability, minimize energy consumption, and also encourage social connectivity and support among the inhabitants. One example can include a high-speed, shared wireless, Wi-Fi connection 401. The units can address manifold social factors by integrating affordable, sustainable housing with community support, providing a scalable solution that offers not only shelter but also possible opportunities for employment, healthcare, and social integration. This approach directly addresses some root causes of homelessness, and promotes a stable and supportive community environment. A supportive community environment can enhance mental well-being and instill a sense of belonging. The substantially circular formation 402 provides a central courtyard 403. This fosters interaction among residents, potentially diminishing the isolation and competitiveness that can be found among people living on the streets. The design thus aligns with studies indicating that reduced social isolation and increased community interaction can significantly lower the risks associated with mental health issues, including depression and anxiety, and even chronic physical illnesses like heart disease and diabetes. The structure of the community 400 is also conducive to faster responses to healthcare emergencies, and better communication with neighbors, to further aid these emergent situations. Mental health and substance abuse support can also be significantly enhanced with the formation 402 utilized in the community 400.

Inherent in the community 400 design is the potential use of shared resources and utilities. This can enhance both the efficiency of construction and the allotment of utilities. A utility tie-in is located in the central courtyard 403, where water supply, electrical supply, and sewage systems can come together. As apparent from FIG. 16, the cluster of the units 100a-e can also enhance the overall structural stability. The interconnectedness of the units 100a-e increases balance and thermal insulation, and reduces any negative effects from the environment. For example, the ability to place beds against shared walls optimizes insulation for the sleeper. Whether there are shared walls or double layers of panels, the sides of each of the units are the adjacent portions are substantially parallel to each other (e.g., parallel outer sides vs. parallel inner sides). Also possible is the combination of two or more of the units 100a-e into a single unit, thus providing a large amount of adaptability of the community 400, at the size presented, or at other sizes, including sizes that are much larger. This is helpful, as families come in many different sizes and have different specific needs. As shown in FIG. 15 a single wall panel 126′ can be used in the common walls between units 100. Thus, the overall cost of each unit is in turn reduced.

Turning particularly to FIG. 15, entrances 404a-e and windows 405a-j are indicated. A community solar panel 343 is shown in the central courtyard 403 (on a post), and is shared by the residents to enhance the effect of each of their individual solar panels 143. Solar panels 143, 343 can be used for harvesting energy, which can enhance sustainability and reduce overall energy costs. If a 72-cell solar panel 143 is sized such that it can be carried on each roof panel 118 of a housing unit 100 having six roof panels 118, such as on a 375 square foot housing unit 100, about 400 Watts can be generated, depending on the sunlight exposure. Assuming an average sunlight exposure of five hours per day, the six solar panels 143 can collectively produce up to about 360 kWh per month. This can be affected, however, but shading, seasonal changes, or variations in sun exposure duration. Some estimates of energy consumption of two individuals inhabiting a single housing unit 100 are in the range of 205 hWh, so that the potential capability of the six solar panels 143 is promising. Even if solar energy capture does not meet the entire energy needs of two people, for example, other steps can be taken in a community 400 for optimization. For example, some housing units 100 may house only one person, thus allowing surplus energy to be stored in a battery and/or distributed to the other units 100 of the community 400. Additionally, each housing unit 100 can remain connected to the electricity grid, ensuring that if the solar panels 143 do not provide sufficient power, particularly at night, the utility grid can supplement the shortfall. Bedding, closets, and other furniture such as dressers, can also be provided in modular form. To save space, a Murphy bed (fold-up) can be incorporated into a wall or piece of furniture.

FIG. 21 illustrates a community 430 comprising a plurality of clusters 431, 432 of sub-communities 400′ of housing units 100. A main street 434, or path, connects to two community streets 435, 436. The western street 435 includes a cluster 431 of thirteen sub-communities 400′ of housing units 100, six on one side of the street 435, six on the opposite side of the street 435, and one at the end of the street 435. The eastern street 436 includes a cluster 432 of thirteen sub-communities 400′ of housing units 100, six on one side of the street 436, six on the opposite side of the street 436, and one at the end of the street 436. Overall, the community 430 includes 26 sub-communities, and 156 total housing units 100.

Each sub-community 400′ comprises a fully enclosed central courtyard 403. Each housing unit has 100 an exterior entrance 404 on the outside of a circle of six housing units 100. The housing units 100 each share two of their six walls with, one with each of two other housing units 100. Thus, the central courtyard 403 is only accessible by a back exit 433, which each housing unit 100 includes. The central courtyard 403 is thus shared by six housing units 100 of a single sub-community 400′, but not by the entire community 430. In some embodiments, one or more housing units of the community 430 can be repurposed as a storage, meeting, utilities, or other shared area. In some embodiments, one or more housing units of the sub-community 400′ can be repurposed as a storage, meeting, utilities, or other shared area.

FIG. 24 illustrates a community 530 comprising a plurality of clusters 528, 529, 531, 532 of sub-communities 400 of housing units 100. A main street 534, or path, connects to four community streets 535, 536, 537, 538. Each of the community streets 535, 536, 537, 538 includes a cluster 528, 529, 531, 532 of thirteen sub-communities 400 of housing units 100, six on one side of the street 535, 536, 537, 538, six on the opposite side of the street 535, 536, 537, 538, and one at the end of the street 535, 536, 537, 538. Overall, the community 530 includes 52 sub-communities, and 260 total housing units 100.

Each sub-community 400 has the same characteristics as described with FIG. 15. In some embodiments, one or more housing units of the community 530 can be repurposed as a storage, meeting, utilities, or other shared area. In some embodiments, one or more housing units of the sub-community 400 can be repurposed as a storage, meeting, utilities, or other shared area.

FIG. 17 illustrates a living space 420 in a housing unit 100. The living space 420 is calculated by the annular surface area 421 (course hatching) between the outer cylindrical wall 422 of the central mast 103, and the inner hexagonal wall surface 423 bounded by the wall panels 126a-f. For the purposes of calculations, the living space surface area 421 is denoted as X. whether the central mast 103 has a circular cross-section (as shown) or a polygonal cross-section, and whether the wall sections 126a-f define a polygon (as shown) or a circle, the surface area 421 is still referred to as annular, and comprises the overall area, minus the area of the central mast 103. For the purposes of consistent calculation, the effect of any internal (e.g., dividing) walls, or other items (furniture, etc.) will be ignored. Thus, the annular surface area 421 in the particular case of the housing unit 100 shown in FIG. 17 (and also FIGS. 2 and 11) is defined as:

The cross-sectional area 424 (fine hatching) of the circular cross-section central mast 103 within the living space (e.g., just above the flooring) is the second portion of this equation, namely C.S. AREA (424)=π×(D/2)2, which is thus subtracted from the hexagonal area.

The housing units 100 are configured to provide a large amount of livable space with only a small area of terrain which must be accessed below the surface. For example, the amount of terrain accessed at its surface need only be approximately the cross-section area of the central mast 103. Thus, the housing units 100 are living space efficient. The ratio (C.S. Area “424”)/X can range from about 185 to about 500, or about 200 to 400, or 220 to 360, or 240 to 320, or 260 to 300.

The one or more wall panels 126, the upper ring 101, and the lower ring 102 together define a living space outer boundary.

Though a large number of materials can be chosen to construct each component of the housing unit 100, many of the choices can include recycled or environmentally friendly materials. These materials can be chosen such that they are durable and promote energy efficiency.

Recycled Steel: Can be used in the frame (e.g. rings 101, 102), central mast 103, 231, tensile wires 104, 105, 270, interior and exterior wall sheets 265, 260, brackets 200, 241, 235, and other structural components. Steel provides exceptional durability and retains a great deal of its strength through one or more recycling processes. Hot-rolled structural steel can be utilized for structural components including the rings 101, 102 and the central mast 102, 231.

Cork: Can be used for the floor panels 165. Cork offers good thermal and acoustic insulation. Cork can be harvested sustainably without damaging trees, thus making it a renewable resource that can enhance both aesthetics and comfort of the housing unit 100.

Cellulose: Can be used for insulation 156, 163, 174, 264. Cellulose can be made from up to 85% recycled paper. It can be treated for fire resistance and pest resistance. Cellulose further provides additional thermal and acoustic insulation. The addition of cellulose can make panels more energy efficient.

The modular design of the housing units 100 accommodates the used of a wide variety of other materials, such as recycled polymeric waste, recycled rubber (natural and synthetic), compress blocks of earth, bamboo, recycled gypsum board, hempcrete, and mycelium-based composite materials. The availability of these myriad material choices allows for flexibility when faced with different financial constraints, environmental considerations, regional availability, or specific structural or aesthetic preferences. The materials provide overall durability in a large variety of environmental conditions, and allow for a fit with variant climates, hot, cold, etc. The materials can provide resistance against corrosion, moisture, and pests, maximizing longevity. Because the majority of the housing unit 100 is suspended above the ground (except the lower portion of the central mast), ground-based environmental stresses are inherently reduced. In a community 400 of units 100, there is some structurally stabilizing effect from an adjacent unit 100 onto another, and vice versa. Sealant material (silicone, urethane, grout, caulking) can be utilized to form a substantially hermetic seal, or at least a water-resistant seal between any of the components. The use of prefabricated concrete can enable immediate construction, as the precured, solidified concrete is placed within a hole in the terrain. This can eliminate delays caused by weather conditions such as rain or freezing temperatures. This method also removes the need for on-site framing, curing, and drying of the concrete, and can significantly accelerate the building process and lower the labor costs.

The housing unit design allows components to be prefabricated and assembled on-site in a rapid manner. Wall, floor, and roof panels, as well as the frame and the mast can be prefabricated and can be subdivided into three to six smaller components, facilitating rapid transport and swift assembly. The hexagonal shape and standardized dimensions can ensure that the units 100 can be easily scalable and can be arranged in various configurations, if necessary, to form larger residential communities, such as the community 400. The components can be mass produced and shipped in bulk, which can lower the cost per unit via the economies of scale. The multiple straightforward design components can be produced with low labor costs and low construction time, further driving down the cost of deployment. The modular nature allows for the components to be compactly packaged and transported efficiently, thus minimizing transportation costs. By focusing on a few key raw materials, pricing can be leveraged, and quality can be maximized.

The central mast 103, 231 acts as the central support for each housing unit 100, anchoring all other components and distributing structural loads efficiently to maintain stability and allowing for nominal concrete 272 to be used for the foundation. The central mast 103, 231 can comprise a solid form or a tubular form, having a hollow center.

The following clauses include examples of apparatus of the disclosure:

A method of manufacture of a housing unit 100 and a subcommunity 400′ or community 400, according to a first embodiment of the present disclosure, follows.

Preparation and Foundation Setup. Utilities are installed underground prior to construction to ensure seamless integration. A concrete footer is installed at a depth determined by local terrain and soil conditions to ensure stability. A mast is anchored into the concrete footer, serving as the central structural support.

Frame assembly: Two frames (e.g., rings 101, 102) are assembled around the mast, creating the primary structure of the unit. Tensile cables are strategically attached, extending from designated vertices through the frames to the top of the mast, effectively suspending the frame.

Structural enhancement: Extrusion plates (e.g., circular plates 254, 255, 256) are secured at critical points, bolted to the mast, and in some embodiments can be supported by radiating tensile cables from the mast's apex, adding additional support and stability.

Flooring installation: Flooring and attic segments are fitted and installed, providing both insulation and structural integrity. In an alternative embodiment, stakes can be strategically placed around the unit's perimeter where the floor does not meet the ground, if any further stabilization of the structure is required, by necessity, or by local laws or regulations. Generally, these stakes are not required.

Wall and roof installation: Walls are erected, followed by the roofing installation, thus ensuring a robust and insulated enclosure. Exterior treatments such as UV-resistant, first-resistant, pest-resistant, and thermal-resistant coatings are applied to enhance durability and performance.

Interior setup and final touches: The interior is fully furnished, and all utility connections are completed to make the unit livable. This process is replicated for the additional units (e.g., four) if constructing a cluster of units. The units of a cluster are interconnected, to form a cohesive cluster, optimizing space and resource use while fostering community interaction.

While embodiments have been shown and described, various modifications may be made without departing from the scope of the inventive concepts disclosed herein.

The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited. Numbers preceded by a term such as “approximately”, “about”, and “substantially” as used herein include the recited numbers (e.g., about 10%=10%), and also represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount.

For purposes of the present disclosure and appended claims, the conjunction “or” is to be construed inclusively (e.g., “an apple or an orange” would be interpreted as “an apple, or an orange, or both”; e.g., “an apple, an orange, or an avocado” would be interpreted as “an apple, or an orange, or an avocado, or any two, or all three”), unless: (i) it is explicitly stated otherwise, e.g., by use of “either . . . or,” “only one of,” or similar language; or (ii) two or more of the listed alternatives are mutually exclusive within the particular context, in which case “or” would encompass only those combinations involving non-mutually-exclusive alternatives. For purposes of the present disclosure and appended claims, the words “comprising,” “including,” “having,” and variants thereof, wherever they appear, shall be construed as open-ended terminology, with the same meaning as if the phrase “at least” were appended after each instance thereof.