Patent Publication Number: US-2017370116-A1

Title: Portable adaptive unibody building

Description:
RELATED APPLICATION DATA 
     This application claims the benefit of Provisional Application for Patent Ser. No. 62/354,751 filed on Jun. 25, 2016. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to the field of portable healthcare buildings. In particular, the present invention is directed to a portable adaptive unibody building. 
     BACKGROUND 
     Individuals affected by debilitating injury or illness often require extra care and/or modified living accommodations. Staying in hospitals or other health care facilities long term may be undesirable, inconvenient, and/or expensive. Additionally, remodeling a patient&#39;s home or the home of a relative/caregiver may be too expensive, take too long, or otherwise be an undesirable option. 
     A temporary living facility that can be removably attached to an existing home can provide a better option in many cases. 
     SUMMARY OF THE DISCLOSURE 
     It is an object of the present invention to provide a portable, accessible living facility that includes a trailer having a chassis, a housing compartment attached to the chassis and including a door, a bedroom area, a bathroom area, and a hoist track running between the bathroom area and the bedroom area, and a connector having a first end and a second end, the connector configured to be removably attached to the housing compartment on the first end and to an existing building on the second end. The connector includes a coil assembly including single ply membrane roofing material over an adjustable coil, a first door panel on the first end configured to be secured over the door, a second door panel on the second end configured to be secured over an opening in an existing building, a floor, a roof frame, and welded wire fabric configured to be wrapped around the coil to hold the coil in a position. 
     It is another object of the present invention to provide a portable living facility having a trailer with a chassis, a housing compartment with a front side and a rear side, the housing compartment including wall plates bolted directly to the chassis, a plurality of structurally insulated wall panels, and a single continuous roof panel, wherein the structurally insulated wall panels have an inside side and an outside side and the structurally insulated wall panels overlap the wall plates on both the inside side and the outside side where the structurally insulated panels are attached to the wall plates wherein the roof panel is attached to the structurally insulated wall panels, and wherein the housing compartment includes a plurality of windows. In addition, the living facility includes a bedroom area in the housing compartment, a bathroom area in the housing compartment, a hoist track attached to the roof panel without additional structural bracing, the hoist track extending from the bedroom area to the bathroom area, a first door on the front side leading to an accessible ramp outside the housing compartment, and a second door on the rear side leading into a connector that is designed and configured to be removably attached on a first end to an outside of the rear side of the housing compartment and designed and configured to be removably attached on a second end to an opening of an existing building, wherein the connector is designed and configured to form a weather-tight connection between the housing compartment and an existing structure and wherein the connector is designed and configured to contain equipment for conveying electrical and plumbing services from an existing structure to the housing compartment. 
     It is another object of the invention to provide a living facility that has a trailer having a chassis that includes a steel perimeter frame with a monolithic structural insulated panel attached, a housing compartment attached to the trailer, the housing compartment including wall plates bolted directly to the chassis, a plurality of structurally insulated wall panels, and a single continuous roof panel, wherein the structurally insulated wall panels have an inside side and an outside side and the structurally insulated wall panels overlap the wall plates on both the inside side and the outside side where the structurally insulated panels are attached to the wall plates and wherein the roof panel is attached to the structurally insulated wall panels, a bedroom area and a bathroom area. The housing compartment also includes a hoist track supported by the roof panel, the hoist track extending from the bedroom area to the bathroom area, a door leading from inside the housing compartment to outside the housing compartment, and a connector designed and configured to be removably attached on a first end to an outside of the housing compartment and to surround the door and designed and configured to be removably attached on a second end to an existing building such that direct access between the existing building and the housing compartment is allowed, wherein the connector is designed and configured to form a weather-tight connection between the housing compartment and an existing structure and wherein the connector is designed and configured to contain equipment for conveying electrical and plumbing services from an existing structure to the housing compartment. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein: 
         FIG. 1  is an exemplary perspective, partially exploded view of an aspect of an embodiment of the invention; 
         FIG. 2A  depicts an alternative trailer in accordance with an embodiment of the present invention; 
         FIG. 2B  is a partial view of the trailer of  FIG. 2A ; 
         FIG. 3  is an exploded view of an exemplary living facility in accordance with aspects of the invention; 
         FIG. 4  is an exploded view of vented siding in accordance with aspects of an embodiment of the invention; 
         FIG. 5  is a plan view of an exemplary living facility in accordance with aspects of the invention; 
         FIG. 6  is an exemplary perspective view of a cavity chase wall with cantilevered sink in accordance with aspects of the invention; 
         FIG. 7A  depicts an aspect of the present invention; 
         FIG. 7B  is a side view of the aspect shown in  FIG. 7A ; and 
         FIG. 8  is an exemplary perspective view of insulated exterior window and door shutters in in accordance with aspects of the invention. 
     
    
    
     DESCRIPTION OF THE DISCLOSURE 
     A living facility suitable for individuals requiring care and/or having mobility issues is provided that is portable and can be removably connected to an existing structure, such as a residence, to allow direct access to the existing structure while remaining on a trailer. The living facility may serve as an alternative to making construction modifications to a residence to accommodate another individual, especially one requiring care and/or having mobility issues since many existing residences are not designed to accommodate those requiring care and/or having mobility issues. 
     The living facility can be made directly accessible through a connection to the existing structure thereby allowing occupants of the existing structure, or host house, to easily and conveniently get to the living facility while affording the patient a sense of privacy and independence. The living facility also allows the occupants of the host house to minimize any disruption and inconvenience associated with adapting the home to meet the needs of the patient and having a patient in the home while maintaining the peace of mind that having the patient on premises provides. 
     The living facility may include electrical connections to the existing structure as well as a plumbing system. Additional features may include an integral hoist track, unibody construction, portable ramp and decking, and a weather-tight, adjustable connector between the living facility and the host house. 
       FIG. 1  depicts a portable living facility  100  of the present invention, which includes a living unit  102  that is supported on and can be transported when necessary on a trailer  104 . Living facility  100  is sized and configured to be transported on roadways. Trailer  104  may have a steel chassis  112 . 
     Alternatively, as shown in  FIGS. 2A-2B , another trailer, trailer  204 , may have a steel perimeter frame  203  (e.g.,  203   a ,  203   b ) with a monolithic structural insulated panel  205  (structural insulated panels are discussed further below) attached to form a unique hybrid trailer chassis  212  to which a living unit, unit  202  (same as unit  102 ), is secured. The design of trailer  204  is lighter while also greatly increasing insulating value and strength. 
     In addition, trailer  104  may include suspension wheel and axle assembly components that are removable to facilitate the insertion of skids. Skids permit living facility  100  to be installed at various heights in order to allow unit  102  to be aligned with a host house. The wheel assembly as well as stabilization jacks of trailer  104  are continuously welded to the chassis. Optionally, trailer  104  may include a removable trailer hitch tongue that can be secured to either side of trailer  104  to facilitate easier installation near the host house. 
     Unit  102  may be constructed to be practically squeak free by using a unibody construction that allows the chassis, floor, walls, and roof to effectively act as one piece. The integral bond between these elements is achieved with a redundant application of mechanical fasteners and a continuous application of structural adhesives. In particular, with reference now to  FIGS. 1-3 , floor  108  of living facility  100  is continuously secured to welded chassis  112  of trailer  104  with heavy duty steel bolts and wooden plates that are bonded to the steel with a structural adhesive. Wall plates  116  are secured directly to chassis  112  with a continuous application of structural adhesive along with integrally welded bolts that fasten wall plates  116  directly to chassis  112 . These integrally welded bolts thus function to secure unit  102  to trailer  104  in manner similar to how a stationary house is typically secured to its concrete foundation. 
     Wall plates  116  are secured to wall panels  120  (e.g.,  120   a - 120   d ), which may preferably be structurally insulated panels, with structural adhesive and continuous panel overlap on both the interior and exterior faces of the wall, which is twice the overlap found in typical construction of manufactured housing where panel overlap only occurs on the outside of the plate. This Structural Insulated Panel construction is also known as a “SIP” construction and structurally insulated panels in accordance with such construction may be manufactured as an engineered assembly of insulating foam with two panels of Oriented Strand Board (OSB), structurally laminated to both broad surfaces. SIP panels can be obtained from a number of vendors such as, Foard Panel, Inc. of Chesterfield, N.H. The continuous panel overlap on both the interior and exterior allows wall panels  120  to be secured continuously to wall plates  116  on both sides of wall panels  120 . Wall panels  120  are also mechanically fastened one to the other and adhered with joint cavities that are foamed in place with a high strength insulating adhesive foam. 
     The unitized wall panel  120  and floor  108  assembly is further solidified by attaching a single continuous roof panel  124  to the tops of wall panels  120 . This provides a rigid structural diaphragm at both the top and bottom of unit  102 . This utilization of a continuous structural skin on the interior and exterior strengthens the unibody construction. All construction corners and seams are secured with separate interior and exterior mending plates that eliminate thermal bridging. 
     A back vented siding may be applied to continuous wood members that surround all sides of unit  102 . As shown in  FIG. 4 , unit  102  may be covered with a vented siding, which may also be referred to as a “Rain Screen.” Vent strapping  128  is attached to wall panels  120  over any sheathing  122  and may be typically 1×3 boards. Siding  126  is attached to vent strapping  128 . Each strapping  128  is secured from top to bottom and thus serves as a continuous structural strap similar to continuous earthquake ties that may be used in frame construction. These many integral straps of solid wood offer another level of redundancy in tying the entire structure of living facility  100  together and air vent space formed has the further advantage of adding to the insulation value of the wall assembly. 
     Turning to  FIG. 5 , the floor plan of unit  102  is designed to comfortably accommodate a patient and be functionally accessible. The floor plan of unit  102  includes a first exterior door  132  that leads to optional deck  130  and/or ramp  134  (not shown in  FIG. 5 ). A second door  136  leads to a second exit or to the interior of a host house through a connector  140  (discussed in more detail below). Various windows  144  (e.g.,  144   a ,  144   b ) provide ample natural light. A first area  148  serves as a bedroom and may include a foldable shelf  152  that can be reached by a patient from a bed and can be folded out of the way to facilitate egress on and off of a bed. 
     A second area  156  serves as a bath area and may include privacy glass panels  158  to separate the bath area from the bedroom, although it will be understood that other materials may be used to provide this separation. Glass panels  158  may be frosted from the floor up to the top of an interior door  160 , which may preferably be a standard height of eighty inches or run from floor to ceiling to accommodate a hoist track (discussed below). Above standard door height, the glass may be transparent to visually extend the ceiling lines from both areas and maximize the apparent size of each area. 
     The bath area includes a roll in shower area  164  that uses an integral floor drain  168 . The drainage area may be created with a shower drain pan that tapers on four sides. A continuous non-slip floor finish covers the entire shower area  164  and slopes down seamlessly to drain  168 . The same flooring flashes up the walls surrounding shower area  164  with a gentle 1.5″ radius curve  170  known as a “cove stick.” The bath area may also include amenities such as a glass grab rail  172  to enhance the interior environment to provide a welcome distinction to the institutional look and feel of hospitals and rehabilitation centers. It will be understood that any suitable grab rail may used, including clear acrylic, for example. Glass grab rail  172  may use laboratory glass billet rods held in place with finished metal hardware and can be finished with custom polished ends and miters where they meet at the corners. In addition, a glass and zinc basin  176  may enhance the interior environment to provide a welcome distinction to the institutional look and feel of hospitals and rehabilitation centers. It will be understood that other materials may be used for basin  176 , such as porcelain. 
     A sink  180  is designed and attached to the plumbing wall such that sink  180  cantilevers over the floor and thus provides wheelchair access from the two open sides, as can be seen in  FIG. 6 . 
     Sink  180  drains into a stainless steel drain trap that may be concealed under a grate  184 , which may be made of teak wood or other suitable material. A chase wall  188  to which sink  180  is attached conceals the mechanical, electrical, and plumbing lines while at the same time facilitating via removable panels easy access to the plumbing, as well as a bath fan. 
     An integral hoist track system may be included within unit  102  to assist with the mobility of the patient. With the above described unibody construction of unit  102 , supplemental bracing may not be necessary to support the hoist track system. This allows for an economical alternative to costly track systems that require special structural bracing before they are installed. The purpose of the hoist track system is to assist in the conveyance of an occupant from the bed to the shower, for example. It is noted that the hoist system may be used by a patient to transport them to any area of a wheel pad. The hoist track system, an exemplary path  192  for which is outlined in  FIG. 5 , includes a hoist plate, such as a wooden structural plate, that is secured to roof panel  124  and insulated ceiling using repetitive fasteners similar to a piano hinge along with a structural adhesive. In this way, the hoist track plate can be concealed flush with the ceiling finish. An optional rope and pulley system enables self-powered transit along the hoist track. A full height shower type door would permit the hoist track to move continuously from the sleeping area to the bathroom. A noise dampening wheel assembly helps minimize the sound made when the hoist track is used. 
     When portable living facility  100  can be placed near a host house, connector  140  may allow direct access between living facility  100  and the host house. Connector  140  is weather-tight and insulated and, in additional to allowing people to go directly between the host house and living facility  100 , can carry the mechanical, electrical, and plumbing services to/from the host house to/from the living facility. 
     When living facility  100  is connected to a host house, connector  140  may include an exterior door  142  (shown in  FIG. 3 ) to facilitate direct access to the host house from the exterior to alleviate the need to use another egress to enter the host house or to have to go through living facility  100  to enter the host house. 
     When a door of the host house is not available or practical, a window opening may be modified such that a portion of the wall below the window sill is removed temporarily to create direct access through connector  140  while living facility  100  is in place. 
     As shown in  FIGS. 7A-7B , connector  140  includes a coil assembly  142  made with single ply membrane roofing over an adjustable coil and secured on both ends to portals  143 . A first portal  143   a  is secured to the host house and a second portal  143   b  is secured to unit  102  around second door  136 . The adjustability of coil assembly  142  permits connector  140  to connect unit  102  to an opening in a host house under a variety of circumstances. For example, there may be obstacles or other reasons that living facility  100  cannot be placed directly in front of an opening of a host house and/or be placed very close to the host house. Once connector  140  is in place, the coil of adjustable coil assembly  142  is tied off with a full wrap of welded wire fabric to secure the final spacing and structure. The interior space of connector  140  may be finished with fire treated thin plywood veneer panels. 
     A floor  141  and roof frame  145  of connector  140  can be cut to length once the spacing between the host house and living facility  100  is determined and be made of one piece structural insulated panels. These panels are then secured to coil assembly  142 . The exterior of coil assembly  142  is wrapped in a blanket of fireproof mineral wool insulation and finished with fire treated thin plywood veneer panels and weatherized with an elastomeric paint or a fully adhered single ply roofing membrane. 
     Unit  102  is energy efficient due to the continuous insulation available through the use of Structural Insulated Panel construction, as well as preferably in some embodiments through the use of insulation in the floor and ceiling. To increase the insulation at the door and window areas, unit  102  may include full coverage insulated shutters  196  (e.g.,  196   a ,  196   b ) made with insulating foam covered with fully adhered metal flashing, as shown in  FIG. 8 . In the closed position, panels  198  (e.g.,  198   a - 198   d ) of shutters  196  significantly reduce heat loss and maintain a dark interior. The recessed side walls accept panels  198  so that they close flush with the exterior wall face, which affords the advantage of lapping the recessed wall to maximize energy efficiency and seal out daylight. Patients in convalescence benefit from the option of closing off natural daylight to enhance the opportunity for sleeping hours when necessary. Panels  198  may be hinged horizontally in order to fold in half (as shown in  FIG. 8 ) so as to act as canopies or sunshades when in the open position. 
     Other features of living facility  100  may include the use of corrugated metal as a special lightweight finish in the bathroom and to hide the hot water heater. Fasteners securing these finishes are easily released to provide easy access to the plumbing walls. Latex reinforced tile adhesive may be used as a lightweight wall finish applied as a finish stucco directly over the wall sheathing. Fire treated wood finish thin veneer plywood may be used as a wainscoting. In addition, fire treated rough sawn wood ceiling panels may be used to conceal wiring and provide a unique natural material finish. 
     Exemplary embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions, and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention.