WO2018075802A1 - Central core for a building - Google Patents

Central core for a building Download PDF

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Publication number
WO2018075802A1
WO2018075802A1 PCT/US2017/057449 US2017057449W WO2018075802A1 WO 2018075802 A1 WO2018075802 A1 WO 2018075802A1 US 2017057449 W US2017057449 W US 2017057449W WO 2018075802 A1 WO2018075802 A1 WO 2018075802A1
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WO
WIPO (PCT)
Prior art keywords
core
framework
building
sides
attaching
Prior art date
Application number
PCT/US2017/057449
Other languages
French (fr)
Inventor
Frank VAFAEE
Original Assignee
Vafaee Frank
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vafaee Frank filed Critical Vafaee Frank
Publication of WO2018075802A1 publication Critical patent/WO2018075802A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34869Elements for special technical purposes, e.g. with a sanitary equipment
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/02Ducting arrangements
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/02Ducting arrangements
    • F24F13/0227Ducting arrangements using parts of the building, e.g. air ducts inside the floor, walls or ceiling of a building

Definitions

  • the present invention relates to the field of building construction and more particularly to the field of prefabricated building construction.
  • HVAC heating, ventilation and air conditioning
  • Homes are built to the current standards and government codes and with the latest available amenities. But such construction does not allow for adaptability and installation of new technology. For example, demolition and reconstruction are often required if the homeowner wishes to upgrade the existing home's layout and fixtures, or they wish to upgrade the infrastructure (plumbing, electrical, communications, etc.). Since the home's infrastructure is so integrated into the superstructure, it is nearly impossible to simply rearrange spaces without also reconfiguring the main systems of the house.
  • Another problem with typical home construction is that it takes a long time. Usually the foundation is poured quickly and the framing is built very fast, but after that it takes a long time to for all the subcontractors to install the electrical, plumbing, etc. A number of inventors have attempted to solve one or other of these problems.
  • This Patent is directed to prefabricated building structures for use in buildings with multiple units.
  • the building will have modules to accept cubicles that are factory built containing an entire bathroom complete with lavatory, bathtub, water closet, and their associated plumbing, electrical wiring, outlets, in-line exhaust fan and the like.
  • the module likewise could be a complete kitchen with appliance, wiring and the like.
  • the prefabricated module that receives the cubicle can be placed to form the building by means of a crane, and if the crane is of sufficient capacity the
  • prefabricated cubicle could be positioned in the module and both installed at the same time.
  • the cubicle will have one wall that is an exterior wall so that at a time to upgrade or repair a fire damaged unit, a refurbished or new unit can be brought on site and the old one removed with the aid of rollers so that it can be rolled out to the crane. It would also be possible to change the type of cubicle from for instance kitchen to bathroom or bathroom to kitchen.
  • This Patent is directed to building modules that can be prefabricated and installed complete in a building structure.
  • the first building module shown in FIG. 1 is for one bathroom and the larger module shown in FIG. 6 is for two rooms. Electrical junction boxes and supply lines to light fan outlets and other fixtures are conveniently extended within the module, making it convenient and easy to connect the module to the electrical supply lines.
  • the toilets are off-the-floor in the water closet.
  • the rooms preferably include toilets with lavatory or wash basins, may further include bath and shower, and may otherwise be laundry rooms, kitchens, custodian rooms, rest rooms, or other kinds of rooms requiring one or more waste conduits to carry away waste water and likely require cold water and electricity and possibly hot water. Such rooms may further require gas dryer vents and other lines or conduits.
  • This Patent is directed to a method and apparatus for constructing multi-rise stacked modules for human occupancy.
  • the construction is in a pinwheel array with the method of construction providing for individual modules that may be readily positioned and removed without affecting the structural integrity of the multi-rise structure.
  • the modules are prefabricated, electrical and water services may be provided through hookups to vertically extending electrical and water surface panels supported about a central open core.
  • the dwelling modules could encompass habitat for residence, office, manufacture, or other human uses.
  • This patent is directed to a multi-level apartment building that includes a vertically extending stairway system with support walls that contain rectilinearly vertically extending utility service conduits used to receive standard utility services such as HVAC, plumbing, exhaust, etc. These conduits extend in vertical straight line paths in the building:
  • the single stair support assembly vertically extending in each of the plurality of vertically aligned apartments functions to consolidate plumbing, HVAC and other utilities into a single assembly having a straight vertical and unobstructed path.
  • the apartment modules preferably include a plurality of pairs of apartments vertically stacked in alternating mirrored patterns, and a plurality of such vertically stacked pairs of apartments horizontally aligned with one another.
  • This reference is directed to interactive building modules that moves between a collapsed configuration which is sized and shaped similarly to a standard shipping container, and an erected configuration where it forms a building of greater space.
  • the modules are connected together to form a single storied or multi-storied building.
  • a series of standardized ceiling panels located within the common area create an accessible services duct for placement of hydraulic, electrical, and data.
  • Hot water is distributed to each module via a continuous hot water loom.
  • a network managing system interactively manages resources. Scenarios for use of modules include virtual space, serviced office, hotel or serviced apartment or residential uses. The scenarios are not mutually exclusive. The design principle enables the same space to be used for different uses over time.
  • the transference of a module from one use to another might include: Changing the furniture; possibly the reprogramming or alternation of certain services to suit the requirements of the occupant and the new use of the module.
  • the internal fit-out may consist of a range of standard plug-in modular components providing a variety of functions and forms.
  • This reference is directed to a prefabricated building comprising: a plurality of exterior and interior wall sections joined together in a selected configuration; a plurality of ceiling panels extending between the walls; a plurality of roof trusses overlying the ceiling panels; a roof supported by the trusses.
  • the prefabricated building further comprises a prefabricated utility core comprising: 1) a plurality of vertical connected core walls extending vertically, one of the core walls providing an exterior wall of the building, an access door in this exterior wall, 2) a main sewer line supported in the core and extending through the exterior core wall and having a plurality of lateral sewer lines extending through the core walls, 3) a main water line extending through the exterior core wall and supported in the core and having a plurality of lateral water lines extending through the core walls, 4) a water heater in the core connected to the main water line, 5) a main hot water line connected to the heater and having a plurality of lateral hot water lines extending through the core walls, 6) a breaker box in the core, 7) a plurality of electrical conduits extending from the breaker box; and 8) fixtures utilizing water and discharging sewage connected to selected the appropriate lateral lines.
  • a prefabricated utility core comprising: 1) a plurality of vertical connected core walls extending vertically, one of the core walls providing
  • U.S. Patent 4,655,011 This reference is directed to a prefabricated building system comprising a portable wall unit having a supporting frame and utility apparatus mounted on the supporting frame.
  • the utility apparatus preferably is adjustably mounted on the supporting frame and may comprise plumbing, electrical, heating and/or cooling apparatus for the rooms adjacent to the portable wall unit in the building in which it is to be installed.
  • Prefabricated wall partitions for the adjacent rooms can be assembled with the portable wall unit before shipment to the building site or at the building site.
  • the portable wall unit is provided with means for aligning the wall unit with the adjacent wall partitions to facilitate the assembly thereof.
  • U.S. Patent 5,127,201 U.S. Patent 5,127,201
  • This reference is directed to a compact service core structure.
  • the walls of the prefabricated compact service core structure are higher than the total height of the floor, wall and ceiling structure of an ordinary one-story residential building, but lower than the total height of a two-story building of any kind.
  • the height of the walls is large enough to e.g. accommodate the serviced fixtures of complete main floor bathroom, kitchen, and possibly laundry and utility rooms, as well as lower parts of the same rooms of the second story of a two-story structure.
  • the height is small enough to make the prefabricated compact service core structure possible to ship on standard low trailers anywhere in the world.
  • the prefabricated compact service core structure allows for factory completion of all major plumbing, heating, ventilation, and electrical work for a two-story building, and easy on site hook-up to sewer, water, gas and electrical services from the bottom of the prefabricated compact service core structure. Ventilation and possibly electrical services may be extended above the top of the core through one or more extension service panels. As all portions of the floor of both stories and high plumbing wall are suspended, pre-manufacturing of the service core in the plan can easily match all custom designed floor heights or deviations from them usually originating from the supply of building lumber of irregular dimensions.
  • the primary module used to transport the entire structure is completed at the factory, requiring no further work at jobsite, with heating and cooling unit, hot water heater, cabinets and appliances, plumbing and light fixtures and accessories installed at the factory in permanent locations.
  • the major exterior walls, slab floor foundation panels, and ceiling/roof panels for all three modules are similarly manufactured in one-piece in full width and the length of the building, eliminating joints, speeding assembly and strengthening the components.
  • the major components of the side modules, consisting of the slab floor foundation panels, ceiling/roof panels and the exterior side walls, are all hinged so that they fold to the side and on top of the primary module. Accessories and wall panels and partitions not hinged are placed on top of the primary module for transportation.
  • Two end walls are bolted to the center module during transportation to the site.
  • the primary module is lowered to the ground and the hinged slab floor foundation panels, which include hinged and folded exterior walls, along with the ceiling/roof panels, are unfolded and permanently fastened in place for that site, but can be refolded if later relocation is needed.
  • the slab floor foundation panels for all three modules are placed directly on the ground or on a pre-built foundation, single or multi-level design. If a pitched roof was ordered, trusses and pre-sized roofing panels transported on top of the primary module are attached to the flat roof of the center module. Two or more of these triple modules can be joined side-to-side or end-to-end or on top of each other, for erection of multiple-unit buildings.
  • none of these inventions allow a house to be built without waiting for installation of infrastructural elements and none of these inventions allow for ease of maintenance or avoidance of damage during remodeling and renovations.
  • none of these inventions represents an entire house building system - that is from manufacture, through distribution, and installation - with access for maintenance and/or upgrade. What is needed is a way of allowing a house to be built without waiting for installation of services and which, when built, would be easy to maintain and remodel.
  • This invention is a core for a building, which has a cuboid framework, at least one story tall, to which all the infrastructural elements for the building are attached. Some of these infrastructural elements are provided with connections for connecting with city services. The elements are so positioned inside the framework that a space is left in the middle for access to all the infrastructural elements.
  • the framework is made of vertical and horizontal metal beams connected to each other.
  • the framework may be in two halves: a front half-framework and a rear half- framework.
  • Walls may be attached to the completed core or to each half-core. Depending on where the core will be located in the building, there will either be one exterior wall section and three interior wall sections, or four interior wall sections. One or more of these walls could be shear walls. Alternatively, the completed core or each half-core may be installed in a pre-constructed room in the building.
  • This invention is also a method of constructing a core for a building, which includes the steps of: connecting vertical and horizontal beams to form a framework of cuboid shape; providing building infrastructural elements, some of which are provided with connections for connecting with city services; attaching a lifting mechanism to the top of the core; and attaching the infrastructural elements inside of the framework in such a way that a space is left in the middle for access to all the infrastructural elements.
  • the completed core or each half-core may be installed in a pre-constructed room in the building.
  • This method may further include the steps of attaching walls, one or more of which may be a shear wall, to the completed core.
  • the core is placed at an outer edge of the foundation, thus one exterior and three interior walls would be needed.
  • the core could be placed inside the building, in which case, four interior walls would be needed.
  • the outsides of the interior wall sections are finished with an interior finish; the outside of the exterior wall section is finished with an exterior finish.
  • the method may further include the steps of: constructing the core at a location remote from the building site; lifting the core with the lifting mechanism; placing the core on a vehicle; transporting the core to the building site on the vehicle; placing the core on the foundation; and attaching the core to the foundation.
  • An embodiment of the method of this invention includes the steps of: connecting a front set of vertical and horizontal beams to form a front half-framework of cuboid shape; connecting a rear set of vertical and horizontal beams to form a rear half- framework of cuboid shape; attaching a front lifting mechanism to the top of the front half; attaching a rear lifting mechanism to the top of the rear half; attaching a set of building infrastructural elements inside the front and rear half-frameworks, some of which are provided with connections for connecting with city services, in such a way that a space is left in the middle of each half-core for access to all the infrastructural elements.
  • This method may further include the steps of: providing a level location remote from the building site; constructing the front and rear half-cores adjacent each other on the level location; testing a least one building infrastructural element; lifting the half- cores with their respective lifting mechanisms; placing the front half-core on a first vehicle; placing the rear half-core on a second vehicle; transporting the half-cores to the building site; placing the half cores on the foundation abutting each other, attaching the half cores to each other; and attaching the competed core to the foundation.
  • a structural hold down which is used to attach the core to the foundation, is attached to the core at least at each corner.
  • At least one interior platform is provided attached to the inside of at least one of the walls.
  • a water heater is installed in the core.
  • Clothes washer, drier and dishwasher connections are located in the core, outside of one of the interior wall sections, and as close as possible to the location where each appliance will be in the completed building.
  • a toilet mechanism is located within at least one of the interior wall sections. This is a special mechanism with a bowl that will be installed later. The mechanism is installed so that the bowl will install from outside of the core.
  • Faucets and mixing valves are attached to the outside of at least one of the interior wall sections.
  • Plumbing and shut off valves interconnect the water main connection, gas main connection, sewer connection, water heater, clothes washer connection, drier connection, dishwasher connection, toilet mechanism, faucet, and mixing valve as necessary and appropriate.
  • the shut off valves are located in the core, adjacent the insides of the interior walls, and as close as possible to the locations where these appliances will be in the completed house, and as close as possible to the interior connections.
  • An irrigation connection connected to the water main, is located outside the exterior wall section.
  • An electric mains connection is located on the exterior of the exterior wall section.
  • a subpanel is located within the core and electrically connected to the electric mains connection.
  • At least one forced air unit is installed within the core.
  • the condenser unit is located outside the core so that hot air produced by the condenser can readily escape.
  • the forced air unit and condenser unit are connected to each other by appropriate ducting.
  • a return air supply duct stub and an air supply duct stub are connected to the forced air unit through one of the interior wall sections.
  • Phone line and television signal connections are located outside the exterior wall section.
  • the phone line connection is punched down to a punch block within the core.
  • the television signal connection is connected to a signal splitter located inside the core.
  • a modem is provided inside the core and electrically connected to either the telephone punch block via a DSL line, or to the signal splitter.
  • the modem may be a wired modem, wireless modem or a wired/wireless modem.
  • This invention may include a server within the core.
  • a security panel is provided inside the core and electrically connected to either the telephone punch block or the modem.
  • a fire suppression unit is located within the core and connected by a plumbing line to the water main connection.
  • Sprinkler line stubs run from the fire suppression unit through the interior walls of the core.
  • At least one in-line exhaust fan is provided within the core.
  • Inlet ducts run through interior walls of the core to the in-line exhaust fan, and an outlet duct runs from the fan to the fresh air louver.
  • a control switch is attached to the outside of at least one of the interior wall sections and is electrically connected to the in-line exhaust fan.
  • a drier vent runs from behind the eventual location of the clothes drier through an interior wall through the core and through the exterior wall.
  • a range hood is attached to the inside of one of the interior walls over the eventual location of the range.
  • a range in-line exhaust fan could be provided in the core. This would be connected via ducting to the range hood. Alternatively, the fan could be incorporated in the range hood. Exhaust ducting could run from the range inline exhaust fan to the fresh air louver, and control wiring could run from the switch in the range hood to the range in-line exhaust fan.
  • a core in-line exhaust fan could be located in the core adjacent the fresh air vent, and a thermostatic control could be located inside the core and electrically connected to the core in-line exhaust fan.
  • This invention may include an internet protocol switching lighting control panel located within the core and electrically connected to the subpanel.
  • This invention may include a water filtration unit in the plumbing between the water main connection and the appliances and the interior connections.
  • This invention may further include a reverse osmosis unit to supply drinking water.
  • the invention may also include a central vacuum system. This comprises a canister in the core, vacuum outlets in the interior walls, and vacuum tubing interconnecting them.
  • This invention may also include an interior room within the core. This is formed by attaching an interior floor to the wall sections one story below the tops of the wall sections.
  • This room is preferably a bathroom, which preferably includes another special toilet mechanism installed within at least one of the interior wall sections. This time the mechanism is installed so that the bowl for the toilet will install from inside of the core.
  • the bathroom also includes faucets and mixing valves attached to the inside of at least one of the interior wall sections. Then plumbing and shut off valves are installed to interconnect the appliances in this interior bathroom with the water main connection, the sewer connection, and the water heater as necessary and appropriate; the shut off valves for these appliances being located under the interior floor as close as possible to the appliances.
  • the present invention is a module that will allow a house to be built without waiting for installation of services. This is because the module is prefabricated with all infrastructural elements already built in. Further, this module allows access to all of the infrastructural elements, thus allowing for ease of maintenance and avoidance of collateral damage during renovations and remodeling. It will be recognized by those familiar with the art to which this invention pertains that this invention could, alternatively, be built on site.
  • the core of this invention separates the infrastructure from the superstructure in a way that allows access to all the infrastructural elements from inside. This is done by prefabricating a module, which contains all the plumbing, mechanical electrical equipment, heating equipment, communications equipment, etc. into one central location that serves the entire house and is easily accessible.
  • a central infrastructure core makes distribution much simpler. Plumbing only needs to go a short distance, making repairs and replacements easier, and electrical and mechanical systems also benefit from the location of the core and are able to radiate out into the home in an efficient manner.
  • the house will preferably be wired with smart technology that will allow the lighting and electrical systems to be remotely observed and controlled. Individual web sites will allow home owners to monitor, control and maintain the health of their house from inside or remotely over the internet.
  • the core has an inherent effect on the architecture of the house in the following ways: 1.
  • the vertical orientation of the core designed to maximize efficiency in floor space and materials, lends itself to a multi-story home; 2. Because of the consolidation of infrastructure in the core, there are fewer ducts and wires running through the home, resulting in fewer essential walls and fixed floor planes; 3. By using lower ceiling heights, three floors can be provided in a space that would normally accommodate only two floors in a traditional home.
  • Modern infrastructure needs to be upgradeable, interconnected and monitorable.
  • a modern infrastructure should provide notification when FAU filters need to be changed, the water filtration needs filter change, a backup battery for the security system or tech rack needs to be changed, etc. With this invention these devices may be easily changed from within the core.
  • infrastructural distribution i.e. pipes, ducts and wires
  • 100% infrastructural source hardware i.e. FAUs, condensers, low voltage controls for lighting or security, water filtration system, electrical panels, fire sprinkler riser, ventilation fans, etc.
  • all hardware is organized and installed so that it is easily accessible. Any aspect of the infrastructure can be updated, maintained, or repaired without touching the finishes. One does not have to open the superstructure or structure to access any aspect of the infrastructure.
  • This invention is equivalent to the crawl space plus attic plus the vertical and horizontal chases and raceways in a traditional building.
  • This invention facilitates the interconnectivity of the modern infrastructural system.
  • the HVAC system needs electricity, hot & cold water, sewer drain, and low voltage control
  • the security system needs electricity, phone, and network connection
  • the water heater needs electricity or gas, ventilation, connection to the water mains and connection to the plumbing fixtures
  • security cameras need electricity, back up batteries, phone system, and access to the network. All of these items and more are provided conveniently and accessibly within the core of this invention.
  • This invention is light and rigid which makes it easy to transport and install. There are no finishes such as tile or paint that would be vulnerable to damage in shipment.
  • Figure 1 is a three-dimensional view of the front half of framework.
  • Figure 1 A is an elevational view of the E side of the framework shown in Figure
  • Figure 1 B is an elevational view of the S side of the framework shown in Figure 1.
  • Figure 1C is an elevational view of the N side of the framework shown in Figure
  • Figure 1 D is an elevational view of the W side of the framework shown in Figure 1.
  • Figure 2 is a three-dimensional view of the rear half of the framework.
  • Figure 2A is an elevational view of the E side of the framework shown in Figure
  • Figure 2B is an elevational view of the W side of the framework shown in Figure 2.
  • Figure 2C is an elevational view of the N side of the framework shown in Figure
  • Figure 2D is an elevational view of the S side of the framework shown in Figure
  • Figure 3 is an elevational view of how front and rear frames are positioned for installation of infrastructural elements.
  • Figure 4 is a three-dimensional view of the front half of framework with the electrical infrastructural element installed.
  • Figure 4A is an elevational view of the S side of the framework shown in Figure 4.
  • Figure 4B is an elevational view of the N side of the framework shown in Figure
  • Figure 4C is an elevational view of the E side of the framework shown in Figure
  • Figure 4D is an elevational view of the W side of the framework shown in Figure 4.
  • Figure 5 is a three-dimensional view of the front half of framework with the exhaust Infrastructural element installed.
  • Figure 5A is an elevational view of the N side of the framework shown in Figure 5.
  • Figure 5B is an elevational view of the E side of the framework shown in Figure
  • Figure 5C is an elevational view of the S side of the framework shown in Figure
  • Figure 5D is an elevational view of the W side of the framework shown in Figure
  • Figure 6 is a three-dimensional view of the rear half of framework with the electrical infrastructural element installed.
  • Figure 6A is an elevational view of the S side of the framework shown in Figure 6.
  • Figure 6B is an elevational view of the E side of the framework shown in Figure
  • Figure 6C is an elevational view of the N side of the framework shown in Figure
  • Figure 6D is an elevational view of the W side of the framework shown in Figure
  • Figure 7 is a three-dimensional view of the rear half of framework with the exhaust infrastructural element installed.
  • Figure 7A is an elevational view of the N side of the framework shown in Figure 7.
  • Figure 7B is an elevational view of the E side of the framework shown in Figure
  • Figure 7C is an elevational view of the S side of the framework shown in Figure
  • Figure 7D is an elevational view of the W side of the framework shown in Figure
  • Figure 8 is a three-dimensional view of the front half of framework with the gas infrastructural element installed.
  • Figure 8A is an elevational view of the N side of the framework shown in Figure 8.
  • Figure 8B is an elevational view of the E side of the framework shown in Figure
  • Figure 8C is an elevational view of the S side of the framework shown in Figure
  • Figure 8D is an elevational view of the W side of the framework shown in Figure
  • Figure 9 is a three-dimensional view of the rear half of framework with the gas infrastructural element installed.
  • Figure 9A is an elevational view of the N side of the framework shown in Figure 9.
  • Figure 9B is an elevational view of the E side of the framework shown in Figure
  • Figure 9C is an elevational view of the S side of the framework shown in Figure
  • Figure 9D is an elevational view of the W side of the framework shown in Figure 9.
  • Figure 10 is a three-dimensional view of the front half of framework with the air supply infrastructural element installed.
  • Figure 10A is an elevational view of the N side of the framework shown in Figure 10.
  • Figure 10B is an elevational view of the E side of the framework shown in Figure
  • Figure 10C is an elevational view of the S side of the framework shown in Figure
  • Figure 10D is an elevational view of the W side of the framework shown in Figure
  • Figure 1 1 is a three-dimensional view of the rear half of framework with the air supply infrastructural element installed.
  • Figure 1 1 A is an elevational view of the N side of the framework shown in Figure 1 1.
  • Figure 1 1 B is an elevational view of the E side of the framework shown in Figure
  • Figure 1 1 C is an elevational view of the S side of the framework shown in Figure
  • Figure 11 D is an elevational view of the W side of the framework shown in Figure
  • Figure 12 is a three-dimensional view of the front half of framework with the fire suppression infrastructural element installed.
  • Figure 12A is an elevational view of the N side of the framework shown in Figure 12.
  • Figure 12B is an elevational view of the E side of the framework shown in Figure
  • Figure 12C is an elevational view of the S side of the framework shown in Figure
  • Figure 12D is an elevational view of the W side of the framework shown in Figure
  • Figure 13 is a three-dimensional view of the front half of framework with the sewer infrastructural element installed.
  • Figure 13A is an elevational view of the N side of the framework shown in Figure 13.
  • Figure 13B is an elevational view of the E side of the framework shown in Figure 13.
  • Figure 13C is an elevational view of the S side of the framework shown in Figure
  • Figure 13D is an elevational view of the W side of the framework shown in Figure 13.
  • Figure 14 is a three-dimensional view of the rear half of framework with the sewer infrastructural element installed.
  • Figure 14A is an elevational view of the N side of the framework shown in Figure
  • Figure 14B is an elevational view of the E side of the framework shown in Figure
  • Figure 14C is an elevational view of the S side of the framework shown in Figure
  • Figure 14D is an elevational view of the W side of the framework shown in Figure 14.
  • Figure 15 is a three-dimensional view of the front half of framework with the water infrastructural element installed.
  • Figure 15A is an elevational view of the N side of the framework shown in Figure
  • Figure 15B is an elevational view of the E side of the framework shown in Figure
  • Figure 15C is an elevational view of the S side of the framework shown in Figure
  • Figure 15D is an elevational view of the W side of the framework shown in Figure 15.
  • Figure 16 is a three-dimensional view of the rear half of framework with the water infrastructural element installed.
  • Figure 16A is an elevational view of the N side of the framework shown in Figure
  • Figure 16B is an elevational view of the E side of the framework shown in Figure
  • Figure 16C is an elevational view of the S side of the framework shown in Figure
  • Figure 16D is an elevational view of the W side of the framework shown in Figure 16.
  • Figure 17 is a three-dimensional view of the front half of framework with all the infrastructural elements installed.
  • Figure 17 A is an elevational view of the N side of the framework shown in Figure
  • Figure 17B is an elevational view of the E side of the framework shown in Figure 17.
  • Figure 17C is an elevational view of the S side of the framework shown in Figure
  • Figure 17D is an elevational view of the W side of the framework shown in Figure 17.
  • Figure 18 is a three-dimensional view of the rear half of framework with all the infrastructural elements installed.
  • Figure 18A is an elevational view of the N side of the framework shown in Figure
  • Figure 18B is an elevational view of the E side of the framework shown in Figure
  • Figure 18C is an elevational view of the S side of the framework shown in Figure
  • Figure 18D is an elevational view of the W side of the framework shown in Figure 18.
  • Figure 19 is an elevational view of the E side of the front and rear half-cores separated but with temporary connections between the infrastructural elements on the two halves for testing.
  • Figure 20 is a three-dimensional view of front and rear half-cores joined together with all systems installed.
  • the wall panels are omitted to provide a view of all installed systems.
  • Figure 21 is a three-dimensional view of the front and rear half-cores joined together and exterior panel applied. For clarity only the framework is shown.
  • Figure 21A is an elevational view from the N side of the assembly shown in Figure 21.
  • Figure 22 is a three-dimensional view of the front and rear half-cores joined together and partially covered with interior and exterior panels or walls installed. For clarity only the framework is shown.
  • Figure 23 is an elevational view of the front and rear half-cores separated and covered.
  • Figure 24 is a three-dimensional view of the front and rear half-cores covered and joined. This is how the fully completed core may appear after installation at the job site.
  • Figure 25 is a three-dimensional view of the bathroom and kitchen joined to the fully assembled core at the building site.
  • Figure 26 is a three-dimensional cut away view showing aspects of interior panel construction.
  • Figure 27 is a three-dimensional cut away view showing further aspects of interior panel construction.
  • Figure 28 is a cross-sectional view illustrating construction of an exterior panel.
  • Figure 29 is a flow diagram describing steps of building a house employing a two-piece core.
  • Figure 30 is a flow diagram describing steps of building a house employing a one-piece core.
  • Figure 31A is a three-dimensional view of the interior of a fully assembled core at the front of the lower level, looking from the front to the rear of the core.
  • Figure 31 B is a three-dimensional view of the interior of a fully assembled core midway along the lower level, looking from the front to the rear of the core.
  • Figure 31 C is a three-dimensional view of the interior of a fully assembled core at the rear of the lower level, looking from the rear to the front of the core.
  • Figure 31 D is a three-dimensional view of the interior of a fully assembled core at the front of the upper level, looking from the front to the rear of the core.
  • Figure 32A is an elevational view of one typical bathroom layout.
  • Figure 32A is an elevational view of a second typical bathroom layout.
  • Figure 33 is an elevational view illustrating a moment frame.
  • Figure 34A is a plan view illustrating one way of locating moment frames in relation to the core.
  • Figure 34B is a plan view illustrating a second way of locating moment frames in relation to the core.
  • Figure 34C is a plan view illustrating a third way of locating moment frames in relation to the core.
  • Figure 34D is a plan view illustrating incorporation of moment frames into the core in place of some horizontal and vertical beams.
  • Figure 34E is a plan view illustrating location of a single moment frame in relation to the core.
  • Figure 34F is a plan view illustrating incorporation of a single moment frame into the core in place of some horizontal and vertical beams.
  • Figure 34G is a plan view illustrating another location for incorporation of a single moment frame into the core in place of some horizontal and vertical beams.
  • Figure 35 is a three-dimensional view showing the preferred placement of the horizontal beams and brackets on the front half-frame.
  • Figure 36 is a three-dimensional view showing the preferred placement of the horizontal beams and brackets on the rear half-frame.
  • the figures from incorporated US Patent Application Serial No. 12/748,751 illustrate aspects of embodiments of the invention pertaining to the building infrastructure incorporated into the completed core.
  • the prefabricated core is constructed as one unit, and is transported to the building site, as a four-sided room including an exterior panel and three interior panels joined together.
  • the embodiment described in the instant application is an improvement of that described in US Patent Application Serial No. 12/748,751.
  • the three appendices to this application are part of and fully incorporated into this application.
  • the core comprises a metal frame inside of which building infrastructural elements are installed in such a way as to leave a space in the middle for access.
  • the prefabricated core 174 is constructed at a location remote from the building site, and may be transported to the building site, as two half-cores 11 , 28. At the building site, the two half-cores 11 , 28 are joined together to form the completed core 174.
  • Figures 1 -45 of application No. 12/748,751 illustrate how the infrastructure components are incorporated into the completed core four-sided room.
  • Figures 1-36 of the instant application illustrate aspects of prefabrication of the core 174 in two half-cores 11 , 28.
  • Advantages to constructing the core 174 in two half-cores 11 , 28 include enabling more than one person to install, in parallel, different components of the various infrastructural elements, e.g., electrical and plumbing.
  • the sizes of the two half-cores 1 1 , 28 are designed so that transport of the two half-cores 11 , 28 to the building site can be accomplished with standard transportation without the need for wide load carriage.
  • some components need to be connected across the midline 178 between the two half-cores 1 1 , 28.
  • connections are made between a component in the front half-core 1 1 and the corresponding component in the rear half-core 28 for testing purposes. After testing, the components are disconnected for transport. Finally, the affected components are reconnected when the two half-cores 11 , 28 are joined at the building site.
  • Figure 20 illustrates the fully assembled, prefabricated core 174 of this invention. While Figure 20 illustrates a two story core 174, those familiar with the field to which this invention pertains will realize that the core 174 can be one or more stories tall.
  • the exterior grade grating 20c is used for access to the core 174.
  • a ladder may be used to climb up, then access to the interior of the core 174 is through the door 154. See also Figures 21 , 24, 25, and 26.
  • the completed core 174 may be covered with panels to form a room. If the core 174 is placed abutting an edge of the foundation, these will be one exterior panel 172 and three interior panels 110. If the core 174 is placed within the foundation edges, these will be three interior panels 1 10.
  • the completed core 174 is constructed of two core half-cores 1 1 , 28. Each half-core 1 1 , 28 of the core 174, described in this application, comprises a cuboid structure having one accessible side 1 12a, 112b.
  • accessible means that no components of any infrastructural element is attached on this side so that people and equipment may pass from the middle space 176a of the front half-core 1 1 to the middle space 176b of the rear half-core.
  • the two half-cores 11 , 28 are placed abutting each other, accessible side 1 12a to accessible side 1 12b.
  • Each half-core 1 1 , 28 of the core 174 may be constructed on a half-framework 10, 26 of vertical 12v and horizontal 12h metal beams. Brackets 22 may be attached at the ends 16 of the horizontal beams 12h. All components are mounted on these half-frameworks 10, 26, and the interior panels 110 and exterior panel 172 may be attached to the brackets 22.
  • the interior panels 1 10 are made of a framework of wood or metal studs 210 covered with interior panel facings 226.
  • the interior panel facings 226 may be plywood or particle board or similar material.
  • the interior panels 110 may be sheet steel.
  • the exterior wall 173 is likewise made of a framework of wood or metal studs 210 covered with an exterior panel facing 236 and coated with an exterior finish 170.
  • the exterior panel facing 236 is, preferably, a polyvinyl chloride composition, or equivalent.
  • the half-cores 1 1 , 28 of this invention are preferably made prefabricated. They are light and rigid which makes them easy to transport. They are sized to be transported on standard semi-trailers without wide load provisions.
  • Figure 1 is a three-dimensional view of the front half 10 of the framework.
  • the half-framework 10 is comprised of beams 12v, 12h.
  • the half-framework 10 is comprised of vertical 12v and horizontal 12h beams attached together so that portions 12p of the horizontal beams 12h protrude past the vertical beams 12v on the E and W sides.
  • Lower, upper, and exterior platforms 20a, 20b ( Figure 2), 20c respectively are included, which may comprise one or more gratings 18.
  • the gratings 18 may be lifted to provide access to components underneath the lower platform 20a.
  • the gratings are slidably positioned on horizontal beams 12h.
  • the gratings can be slid one way or another to provide access to the components above the upper platform 20b.
  • the space between the lower 20a and exterior 20c platforms and the upper platform 20b comprises a first story 35.
  • the space between the upper platform 20b and the top 56a comprises a second story 37.
  • the lower platform 20a and the exterior platform 20c become the floor of the first story 35 and the upper platform 20b becomes the floor of the second story
  • Brackets 22 may be attached to the ends 16 of the horizontal beams 12h, on the S, E and W sides of the framework 10. Interior panels 1 10 may be eventually attached to the brackets 22 on the S, E and W sides and an exterior panel 172 may be eventually attached to the N side. See Figure 24.
  • Figure 2 is a three-dimensional view of the rear half 26 of the framework. This is how the half-framework 26 may be fabricated in the factory. The half-framework 26 is comprised of vertical 12v and horizontal 12h beams attached together so that portions 12p of the horizontal beams 12h protrude past the vertical beams 12v on the E and W sides. Lower and upper platforms 20a, 20b are included, which may comprise one or more gratings 18.
  • the gratings 18 may be lifted to provide access to components underneath the lower platform 20a.
  • the gratings are slidably positioned on horizontal beams 12h. The gratings can be slid one way or another to provide access to the components above the upper platform 20b.
  • the space between the lower 22a platform and the upper platform 20b comprises a first story 35.
  • the space between the upper platform 20b and the top 56a comprises a second story 37.
  • the lower platform 20a becomes the floor of the first story 35 and the upper platform 20b becomes the floor of the second story.
  • the first 35 and second 37 stories in the front and rear halves 11 , 28 are continuous and co-extensive
  • Brackets 22 may be attached to the ends 16 of the horizontal beams 12h, on the S, E and W sides. Interior panels 1 10 may be eventually attached to the brackets 22 on the S, E and W sides. See Figure 24.
  • the horizontal beams 15h and brackets 22 may be classified as shown in the following tables.
  • Brackets 22 are classified by which way they face: southward 22s, northward 22n, eastward 22e and westward 22w. Brackets face in a particular direction if they can be attached to an element on that side. In other words, a southward facing bracket is positioned so that it can attach to an element on its south side.
  • Figure 3 is an elevational view from the E side, showing how front 10 and rear 26 frameworks may be positioned for installation of the infrastructural elements.
  • Figure 4 is a three-dimensional view of the front half of the framework 10 with the electrical infrastructural element installed. Shown are an outdoor electric meter 30, connected to a subpanel 34 by electric wiring (not shown) running through flexible metal conduit 38. Also shown is lifting hook 42 attached to a lifting beam 40, which together comprise the lifting mechanism 44 used to lift the half-framework 10.
  • Figure 5 is a three-dimensional view of the front half of the framework 10 with the exhaust infrastructural element installed. Shown is exhaust duct 50. Dotted arrows show the direction of air flow.
  • Figure 6 is a three-dimensional view of the rear half of the framework 26 with the electrical infrastructural element installed. Shown are another subpanel 34 and a junction box 46 connected together by flexible metal conduit 38. Also shown is the lifting mechanism 44.
  • Figure 7 is a three-dimensional view of the rear half of the framework 26 with the exhaust infrastructural element installed. Shown is in-line exhaust fan 54 connected to the exhaust duct 50. Dotted arrows show the direction of air flow.
  • Figure 8 is a three-dimensional view of the front half of the framework 10 with the gas infrastructural element installed. Shown is gas pipes 58. A dotted arrow shows the direction of gas flow.
  • Figure 9 is a three-dimensional view of the rear half of the framework 26 with the gas infrastructural element installed. This is how the gas system may be installed on the half-framework 26 in the factory. Shown is gas pipe 58.
  • Figure 10 is a three-dimensional view of the front half of the framework 10 with the air supply infrastructural element installed. Shown are furnace 62, heating coil 66, and furnace vent 64 connected together by a return plenum 70, a first supply plenum 74, and an air supply duct 82. Dotted line arrows show the direction of air flow.
  • Figure 1 1 is a three-dimensional view of the rear half of the framework 26 with the air supply infrastructural element installed. Shown are second supply plenum 78, third supply plenum 80, air supply ducts 82, and return air supply duct 86 connected together as illustrated. Dotted line arrows show the direction of air flow.
  • Figure 12 is a three-dimensional view of the front half of the framework 10 with the fire suppression infrastructural element installed. Shown are the fire suppression drain 90, fire sprinkler riser 94 and distribution pipe 96 connected together as illustrated. Dotted line arrows show the direction of water flow.
  • Figure 13 is a three-dimensional view of the front half of the framework 10 with the drain and sewer infrastructural element installed. Shown are the drain pipes 98, the internal sewer 100, and sewer vent pipe 99 connected together as illustrated. A dotted line arrow shows the direction of air flow in the vent pipe 99.
  • Figure 14 is a three-dimensional view of the rear half of the framework 26 with the sewer infrastructural element installed. Shown are the drain pipe 98, the internal sewer 100, and sewer vent pipe 99 connected together as illustrated. A dotted line arrow shows the direction of air flow in the vent pipe 99.
  • Figure 15 is a three-dimensional view of the front half of the framework 10 with the water infrastructural element installed. Shown are the cold water influx pipe 102, tankless water heater 106, hot water pipe 103, air inlet 104, and exhaust 108 for combustion gasses. Dotted line arrows show direction of air flow.
  • Figure 16 is a three-dimensional view of the rear half of the framework 26 with the water infrastructural element installed. Shown is the cold water influx pipe 102 and hot water pipe 103.
  • Figure 17 is a three-dimensional view of the front half-core 11. It is comprised of the front half-framework 10 with all the infrastructural elements installed. The infrastructural elements are installed on the framework 10 so as to leave a space 176a in the middle. The accessible side 112a is also illustrated. The space 176a and accessible side 112a allow access to all the infrastructural elements for service, repair or replacement.
  • Figure 18 is a three-dimensional view of the rear half-core 28. It is comprised of the rear half-framework 26 with all the infrastructural elements installed. The infrastructural elements are installed on the framework 26 so as to leave a space 176b in the middle. The accessible side 112b is also illustrated. The space 176b and accessible side 112b allow access to all the infrastructural elements for service, repair or replacement.
  • Figure 19 is an elevational view of the E side of the front 10 and rear 26 halves of the framework with all infrastructural elements installed, with the front 10 and rear 26 half-frameworks separated but with temporary connection of the infrastructural elements on the two half-cores 11 , 28, for testing. Indicated are temporarily joined exhaust ducts 50, fire suppression drain 90, cold water influx pipe 102, gas pipe 58, and internal sewer 100. As noted earlier, once the two half-cores 1 1 , 28 are tested, the temporary connections are cut.
  • Figure 20 is a three-dimensional view of the front 11 and rear 28 half-cores joined together with all infrastructural elements installed.
  • Figure 21 is a three-dimensional view of the front 10 and rear 26 half-frameworks joined together and including the exterior wall 173. For clarity only the half-frameworks 10, 26 are shown - i.e. the infrastructural elements are not shown.
  • Figure 21A is an elevational view from the N (exterior wall) side of the assembly shown in Figure 21.
  • Figure 22 is a three-dimensional view of the front 10 and rear 26 half-frameworks joined together and partially covered. For clarity the infrastructural elements are not shown.
  • Figure 23 is an elevational view of the E side of the front 1 1 and rear 28 half- cores separated and covered.
  • the coverings may comprise interior panels 1 10 mounted on the half-frameworks 10, 26. This is how the front 1 1 and rear 28 half-cores may appear after completion in the factory, and ready for transport to the building site. Also visible are sections of the flexible metal conduit 38, a junction box 46, an LB box148, a satellite cable conduit 142, and the roof drain 138. Also shown are how the second story ledger 132 and ceiling ledger 136 are installed on the interior panels 110.
  • Figure 24 is a three-dimensional view of the front 11 and rear 28 half-cores covered and joined. This is how the completed core 174 appears after installation at the building site.
  • conduit for satellite cable 142 and solar panel feed 146 vent covers 150, interior panel 1 10, roof 114, exterior finish 170, ledger boards 132, 136, security camera 152, air intake louver 158, and drier vent 150h.
  • drier vent 150h Several positions for the drier vent 150h are shown. These components may be installed during manufacture of the core 174, except for roof 114 which is generally installed at the building site.
  • Figure 25 is a three-dimensional view of the bathroom 118 and kitchen 122 joined to the fully assembled, prefabricated core 174. Also illustrated are the roof 114, ground floor 126, ceiling of ground floor/floor of second story 130, ceiling of second story 134, access door 154, air intake louver 158, air conditioner condenser 162, city water main 166, exterior wall 173, faucet 198, sink 202, bathtub 204, range hood 194, stove 190. All the illustrated components are installed after the core 174 is installed at the job site.
  • Figure 26 is a three-dimensional cut away view showing aspects of wall construction. The wall could be a shear wall. Elements illustrated are the second story Iedger132, ceiling ledger 136, studs 210, the top plate 214, the interior panel 1 10, the exterior wall 173, the exterior finish 170, the sill 218, and a steel beam 240.
  • Figure 27 is a three-dimensional cut away view showing further aspects of interior panel 110 construction. Elements illustrated are the studs 210, the top plate 214 and the interior facing 226. North 22n and south 22s facing brackets attach to the N and S sides of the studs 210. The east facing bracket 22e attaches to the W side of a stud 210; and the west facing bracket22w attaches to the E side of a stud. Persons familiar with the art to which this invention pertains will recognize that this construction is typical for interior wall construction in the United States.
  • Figure 28 is a cross-sectional view illustrating construction of an exterior panel 172. It comprises an exterior facing 236 fastened to studs 210. Further to the exterior is an exterior finish 170 separated from the exterior facing 236 by an air gap 230.
  • Figure 29 is a flow diagram illustrating the steps of building a house employing a two-piece core 174.
  • steps 510 and 520 the two half-frameworks 10, 26 are built. They are then placed next to each other and separated by a small distance on a level sill 218, step 530. Preferably steps 510 through 530 are done at a site remote from the site where the house will be built but could be done at the building site.
  • step 540 the infrastructural elements are installed in each half-framework 10, 26. Because components of some infrastructural elements are installed in each half- framework 10, 26, it may be necessary to make temporary connections across the gap, step 550.
  • step 560 the interior panels 1 10 are attached to the S, E and W sides of the half-frameworks 10, 26 and the exterior wall 173 is attached to the N side of the front half-framework 26. The interior panels 110 and wall 173 can be attached prior to or after the next step, but this the preferred timing. Ledger boards 132, 136 may be attached to the interior panels. Infrastructural elements are tested, step 570. After all infrastructural elements pass testing, the temporary connections are disconnected, step 580.
  • step 590 the two half-cores 11 , 28 are lifted, tilted and laid on separate flatbed trucks. They are then trucked to the building site, step 600, where they are lifted of the trucks and tilted upright.
  • the foundation may be laid at the building site at any point in the prior steps but it must be laid prior to placing the half-cores 1 1 , 28 at the building site, step 605.
  • the half-cores 11 , 28 are placed on the foundation abutting each other, accessible side 1 12a to accessible side 112b with the exterior wall 173 at a location on the foundation that will become the exterior of the house.
  • steps 630 and 640 the half-cores 11 , 28 are fastened to each other, the half- frameworks 10, 26 are attached to the foundation, and components of infrastructural elements in each half are connected to each other as necessary.
  • the building is constructed around the core, wet components (see, for example Figure 25) are installed in the proper locations on the core, and utilities (electrical, plumbing, etc.) are run from the core to wherever they are needed in the house, step 650. After this construction proceeds as follows: Erection of prefabricated wall panels for the rest of the house on the foundation.
  • Openings are left between panels for placement of doors and windows.
  • roofing 114 Installation of windows and doors. Construction of roofing 114 on the top 56 of the core 174 and prefabricated wall panels 110, 172.
  • Figure 29 is a flow diagram illustrating the steps of building a house employing a one-piece core 174.
  • steps 710 and 720 the core framework 8 is built and placed on a level sill 218. Preferably these steps are done at a site remote from the site where the house will be built, but could be done at the building site.
  • the infrastructural elements are installed in the framework at step 730, and tested at step 740
  • step 750 the interior panels 1 10 are attached to the S, E and W sides of the frameworks and the exterior wall 173 is attached to the N side.
  • Ledger boards 132, 136 may also be attached to the interior panels.
  • step 760 the core 174 is lifted and laid on a flatbed truck. It is then trucked to the building site, step 770, where it is lifted off the truck, step 780, and placed on the foundation, step 790.
  • the foundation may be laid at the building site at any point in the prior steps but it must be laid prior to placing the core 174 at the building site, step 775.
  • the core 174 is placed on the foundation step 790 with the exterior wall 173 at a location on the foundation that will become the exterior of the house.
  • step 800 the framework 8 of the completed core 174 is fastened to the foundation.
  • the building is constructed around it.
  • Wet components see, for example Figure 25
  • utilities electrical, plumbing, etc.
  • Openings are left between panels for placement of doors and windows.
  • One embodiment of this invention is a core 174 for a building, which has a rectangular prism or cuboid shape.
  • “rectangular prism” will be used interchangeably with “cuboid”.
  • the dictionary definition of "cuboid” is a “rectangular parallelepiped", which is a box shape.
  • N, E, S and W the sides of the core 174 will be designated throughout this document as N, E, S and W. In no way does this imply the direction in which this invention faces.
  • the core 174 is built on a framework 8 of vertical 12v and horizontal 12h beams connected to each other as illustrated in Figures 1 and 2. Portions 12p of the horizontal beams 12h protrude past the vertical beams 12v on the E and W sides.
  • infrastructural elements are attached inside of the framework 8 so as to leave a space 176 for access in the middle. Some of these infrastructural elements are provided with connections for connecting with city services, such as water, gas, sewer, phone, cable and electricity. This then is the core 174.
  • An interior panel 1 10 may be attached to the E, S and W sides and an exterior wall 173 is attached to the N side of the core 174.
  • an interior panel 110 is one that is suitable for installation in the interior of a building
  • an exterior panel 172 is one that is suitable for installation on the exterior of a building.
  • the major difference between these panels is that the exterior panel 172 is constructed to withstand the elements whereas an interior panel 1 10 does not have to be. Persons familiar with the art to which this invention pertains will know the difference in such panels.
  • the framework 8 may be in two halves: a front half-framework 10 and a rear half- framework 26.
  • the front half-framework 10 includes a front E half-side, a front W half- side and the N side and the rear half-framework 26 includes a rear E half-side, a rear W half-side and the S side.
  • the front S side of the front half-framework 10 and the rear N side of the rear half-framework 26 are open.
  • a second embodiment of this invention is a core 174 for a building which has a cuboid front half-framework 10, and a cuboid rear half-framework 26.
  • the front half- framework 10 has a front top 56a, front E and W half-sides, and front N and S sides, with the front S side being accessible.
  • the rear half-framework 26 has a rear top 56b, rear E and W half-sides, and rear N and S sides, with the rear N side being accessible.
  • the designations N, E, S, and W are for convenience, and do not imply the direction in which the invention faces.
  • the half-frameworks 10, 26 are made of vertical 12v and horizontal beams connected to each other as illustrated in Figures 1 and 2. Portions 12p of the horizontal beams 12h protrude past the vertical beams 12v on the E and W sides.
  • Lifting mechanisms 44 comprising a lifting beam 40 and lifting hook 42 are attached to the front top 56a and the rear top 56b.
  • infrastructural elements are attached inside the front 10 and rear 26 half- frameworks, leaving a space 176a, 176b in the middle. Some of these infrastructural elements are provided with connections for connecting with city services, such as water, gas, sewer, phone, cable and electricity.
  • city services such as water, gas, sewer, phone, cable and electricity.
  • An interior panel 110 is attached to the front E and W half-sides, the rear E and W half-sides, and the rear S side, and an exterior wall 173 is attached to the front N side of the half-cores 11 26.
  • This invention further describes a method of constructing a core 174 for a building, which includes the steps of: connecting vertical 12v and horizontal 12h beams to form a framework 8 of cuboid shape having a top, and N, E, S and W sides with portions 12p of the horizontal beams 12h protruding past the vertical beams 12v; attaching a lifting mechanism 44 to the top; attaching a number of building infrastructural elements inside of the framework 8 so as to leave a space 176 in the middle for access; some of the infrastructural elements being provided with connections for connecting with city services; attaching an interior panel 110 to the E, S and W sides; and attaching an exterior wall 173 to the N side.
  • the method may further include the steps of: pouring a foundation at a building site; constructing the core 174 at a location remote from the building site: lifting the core 174 with the lifting mechanism 44; placing the core 174 on a vehicle; transporting the core 174 to the building site on the vehicle; placing the core 174 on the foundation so that the exterior wall 173 is at an exterior of the building; and attaching the core 174 to the foundation.
  • An embodiment of this invention describes a method of constructing a core 174 for a building, which includes the steps of: connecting a set of vertical 12v and horizontal 12h beams to form a front half- framework 10 of cuboid shape, as shown on Figures 1 and 2 with portions 12p of the horizontal beams 12h protruding past the vertical beams 12v; connecting a set of vertical 12v and horizontal 12h beams to form a rear half- framework 26 of cuboid shape, with portions 12p of the horizontal beams 12h protruding past the vertical beams 12v; attaching lifting mechanisms 44 to the tops 56a, 56b of the front 10 and rear 26 half- frameworks; attaching building infrastructural elements inside the front 10 and rear 26 half- frameworks 10, 26 so that a space 176a, 176b is left in the middle for access; some of the infrastructural elements being provided with connections for connecting with city services; components of some infrastructural elements being installed in both half- frameworks 10, 26;
  • This method may further include the steps of: pouring a foundation at a building site; providing a level location remote from the building site; constructing the front 1 1 and rear 28 half-cores adjacent each other on a sill on the level location; testing one or more building infrastructural elements as appropriate; lifting the half-cores 11 , 28 with their respective lifting mechanisms 44; placing the front half-core 1 1 on a first vehicle; placing the rear half-core 28 on a second vehicle; transporting the half-cores 1 1 , 28 to the building site; and placing the half-cores 1 1 , 28 on the foundation with the S wall (accessible sidel 12a) of the front half-core 11 abutting the N wall (accessible side 112b) of the rear half-core 28 and the exterior panel 172 at the exterior of the building.
  • Brackets 22 may be attached to the protruding portions 12p.
  • the interior panels 110 may be constructed by attaching studs 210 to interior facings 226. Then the studs 210 of the interior panels 110 may be attached to the brackets 22 on the E and W sides of the front framework 10 and the E and W and S sides of the rear half-framework 26.
  • the exterior panel 172 may be constructed by attaching studs 210 to exterior facings 236. Then the studs 210 of the exterior panel 172 may be attached to the brackets 22 of the N.
  • the studs 210 and facings 236, 226 may be wooden.
  • a second story ledger 132 may be attached through the interior facings 226 and into the studs 210 on the S, E and W sides at a level to support a floor.
  • a ceiling ledger 136 may be attached through the interior facings 226 and into the studs 210 on the S, E and W sides at a level to support a ceiling 130, 134.
  • City services include water, gas, sewer, phone, cable and electricity.
  • the infrastructural elements include: an electrical infrastructural element ( Figures 4,6); an exhaust infrastructural element ( Figures 5, 7); a gas infrastructural element ( Figures 8, 9); an air supply infrastructural element ( Figures 10, 1 1); a fire suppression infrastructural element; a phone infrastructural element; a lighting infrastructural element; a sewer infrastructural element ( Figures 13, 14); and a water infrastructural element ( Figures 15, 16).
  • an electrical infrastructural element Figures 4,6
  • an exhaust infrastructural element Figures 5, 7
  • a gas infrastructural element Figures 8, 9
  • an air supply infrastructural element Figures 10, 1 1
  • a fire suppression infrastructural element a phone infrastructural element
  • a lighting infrastructural element a lighting infrastructural element
  • the infrastructural elements may further include: a TV distribution infrastructural element; a Wi-Fi infrastructural element; and a water softening infrastructural element.
  • the electrical infrastructural element components may include: an outdoor electric meter 30, connected to subpanels 34, junction boxes 46, and LB boxes 148 by electric wiring (not shown) running through flexible metal conduit 38.
  • the exhaust infrastructural element may include an in-line exhaust fan 54 and interconnecting ducting 51.
  • the gas infrastructural element may include interconnecting gas pipes 58 with stubs at the ends for connecting the various gas powered appliances.
  • the air supply infrastructural element may include: a furnace 62; a heating coil 66; a return plenum 70; three supply plenums 74, 78, 80; an air supply duct 82; and a return air supply duct 86 connected together as illustrated on Figures 10 and 11.
  • the fire suppression infrastructural element may include: a fire sprinkler riser 94 connected to connect to a city water main; and a fire suppression drain 90 and distribution pipe 96 connected to the fire sprinkler riser 94. Dotted line arrows show the direction of water flow.
  • the phone infrastructural element may include: a punch block for connection to a city phone service; a wire connected to the punch block, and adapted to connect to a telephone.
  • the lighting infrastructural element may include: an internet protocol lighting control panel electrically connected to a subpanel 34.
  • the sewer infrastructural element may include: drain pipes 98, sewer lines'! 00, and sewer vent pipes 99 connected together as illustrated.
  • the drain lines are adapted for attachment to a sink, toilet, shower 340, tub 204, etc.
  • the drain pipes 98 are connected to the internal sewer 100.
  • the water infrastructural element may include: incoming cold water influx pipe
  • the incoming cold water influx pipe 102 adapted at its front end to connect to a city water main 166, is split into a number of branches and is adapted at the ends of the branches to connect to a cold water appliance such as faucets, toilets, etc.
  • a tankless water heater 106 is also connected to the cold water influx pipe 102 at its inlet and a hot water pipe 103 at its outlet.
  • the hot water pipe 103 is also split into a number of branches and is adapted the ends of the branches to connect to hot water appliance such as faucets, shower heads, etc.
  • the TV distribution infrastructural element may include a coaxial cable to a TV antenna, satellite dish or a city cable TV service.
  • the Wi-Fi infrastructural element may include a wireless modem connected to a city internet service.
  • the water softening infrastructural element may include a water softener connected in the water influx pipe 102.
  • the core 174 only provides lateral support to the building. If superior structural support is needed, the core 174 may be attached to or incorporate a moment frame 364.
  • a moment frame 364, or more properly a moment- resisting frame is a "rectilinear assemblage of beams and columns, with the beams rigidly connected to the columns. Resistance to lateral forces is provided primarily by rigid frame action - that is, by the development of bending moment and shear force in the frame members and joints. By virtue of the rigid beam-column connections, a moment frame cannot displace laterally without bending the beams or columns depending on the geometry of the connection.
  • Moment frames 364 are usually made one horizontal, steel, I beam 368h and two vertical, steel, I beams 368v, welded or fastened together at the corners and connected to or embedded in the foundation 372.
  • moment frames can be designed for each application. In that case the frame must be engineered to meet all structural requirements.
  • a number of standard moment frames, which have been pre-engineered to meet all structural requirements are available for purchase. Appendix I of priority document U.S. Patent Application No. 15/298,709 is a catalog of ready-made moment frames and their mechanical properties and incorporated by reference in its entirety.
  • Moment frames 364 may be placed outside of the core 174 in several locations (see Figures 34A and 34B) or inside the core 174 (see Figure 34C) and then firmly attached to the horizontal 12h and vertical 12v beams of the core 174. Alternatively, moment frames 364 may be incorporated in the core, in place of at least one set of horizontal 12h and vertical 12v beams. See Figure 34D.
  • moment frames 364 may be used with this invention 174.
  • Figures 34A through 34D illustrate use of two moment frames 364 in association with this invention 174. Instead, depending on exact design and mechanical requirements needed, only one moment frame 364 may be needed.
  • Figures 34E through 34G illustrate use of a single moment frame 364 in association with this invention 174
  • Rear half framework 28 Rear half of fully assembled, prefabricated core, or rear half-core
  • Drain connection for connection to e.g. toilet or sink drain.

Abstract

A prefabricated core for a building with all services already built in. The core serves as: 1. the housing for all the home's mechanical, plumbing and electrical sources, and 2. a major structural support, providing lateral support to the structure. This invention allows access to all of the services thus allowing for ease of maintenance and avoidance of collateral damage during renovations and remodeling.

Description

CENTRAL CORE FOR A BUILDING
Technical Field
The present invention relates to the field of building construction and more particularly to the field of prefabricated building construction.
Background Art
Currently, houses are built in a standard sequence. The following is a typical sequence. The order of the sequence can be modified in various ways.
Grading and site preparation
Construction of foundation. Typically premixed concrete is poured or pumped into molds constructed on the site.
Erection of framing on the foundation. Wood and steel are usually used for framing members. Openings are left in the framing for placement of doors and windows.
Installation of windows and doors.
Construction of roofing on top of the framing.
Installation of exterior walls and/or siding.
Installation of rough electrical wiring.
Installation of rough plumbing.
Installation of rough heating, ventilation and air conditioning (HVAC). Installation of alarm system wiring. Installation of phone system wiring. Installation of local area network LAN wiring. Installation of insulation in exterior walls and attic. Attachment of drywall to interior of framing. Installation of underlayment for floors. Installation of trim. Painting.
Installation of finish electrical, such as switches and lights. Installation of finish alarm system.
Installation of LAN and phone system jacks and cover plates. Installation of bathroom and kitchen counters and cabinets Installation of finish plumbing, such as sinks, toilets and faucets. Installation of carpet and other flooring. Installation of HVAC units. Hookup to water main or well. Hookup to sewer or septic system Correction of problems.
Homes are built to the current standards and government codes and with the latest available amenities. But such construction does not allow for adaptability and installation of new technology. For example, demolition and reconstruction are often required if the homeowner wishes to upgrade the existing home's layout and fixtures, or they wish to upgrade the infrastructure (plumbing, electrical, communications, etc.). Since the home's infrastructure is so integrated into the superstructure, it is nearly impossible to simply rearrange spaces without also reconfiguring the main systems of the house. Another problem with typical home construction is that it takes a long time. Usually the foundation is poured quickly and the framing is built very fast, but after that it takes a long time to for all the subcontractors to install the electrical, plumbing, etc. A number of inventors have attempted to solve one or other of these problems.
(1) U.S. Patent 4,447,996
This Patent is directed to prefabricated building structures for use in buildings with multiple units. The building will have modules to accept cubicles that are factory built containing an entire bathroom complete with lavatory, bathtub, water closet, and their associated plumbing, electrical wiring, outlets, in-line exhaust fan and the like. The module likewise could be a complete kitchen with appliance, wiring and the like. The prefabricated module that receives the cubicle can be placed to form the building by means of a crane, and if the crane is of sufficient capacity the
prefabricated cubicle could be positioned in the module and both installed at the same time. The cubicle will have one wall that is an exterior wall so that at a time to upgrade or repair a fire damaged unit, a refurbished or new unit can be brought on site and the old one removed with the aid of rollers so that it can be rolled out to the crane. It would also be possible to change the type of cubicle from for instance kitchen to bathroom or bathroom to kitchen.
(2) U.S. Patent 6,301 ,838
This Patent is directed to building modules that can be prefabricated and installed complete in a building structure. The first building module shown in FIG. 1 is for one bathroom and the larger module shown in FIG. 6 is for two rooms. Electrical junction boxes and supply lines to light fan outlets and other fixtures are conveniently extended within the module, making it convenient and easy to connect the module to the electrical supply lines. Likewise, with the dryer vent, hot and cold water lines, gas conduit and the waste lines. The toilets are off-the-floor in the water closet. The rooms preferably include toilets with lavatory or wash basins, may further include bath and shower, and may otherwise be laundry rooms, kitchens, custodian rooms, rest rooms, or other kinds of rooms requiring one or more waste conduits to carry away waste water and likely require cold water and electricity and possibly hot water. Such rooms may further require gas dryer vents and other lines or conduits. (3) U.S. Patent 5,528,866
This Patent is directed to a method and apparatus for constructing multi-rise stacked modules for human occupancy. The construction is in a pinwheel array with the method of construction providing for individual modules that may be readily positioned and removed without affecting the structural integrity of the multi-rise structure. The modules are prefabricated, electrical and water services may be provided through hookups to vertically extending electrical and water surface panels supported about a central open core. The dwelling modules could encompass habitat for residence, office, manufacture, or other human uses.
(4) U.S. Patent 7,540, 120
This patent is directed to a multi-level apartment building that includes a vertically extending stairway system with support walls that contain rectilinearly vertically extending utility service conduits used to receive standard utility services such as HVAC, plumbing, exhaust, etc. These conduits extend in vertical straight line paths in the building: Thus the single stair support assembly vertically extending in each of the plurality of vertically aligned apartments functions to consolidate plumbing, HVAC and other utilities into a single assembly having a straight vertical and unobstructed path. The apartment modules preferably include a plurality of pairs of apartments vertically stacked in alternating mirrored patterns, and a plurality of such vertically stacked pairs of apartments horizontally aligned with one another. (5) U.S. Pre-Grant Publication 2009/0031642
This reference is directed to interactive building modules that moves between a collapsed configuration which is sized and shaped similarly to a standard shipping container, and an erected configuration where it forms a building of greater space. The modules are connected together to form a single storied or multi-storied building. A series of standardized ceiling panels located within the common area create an accessible services duct for placement of hydraulic, electrical, and data. Hot water is distributed to each module via a continuous hot water loom. A network managing system interactively manages resources. Scenarios for use of modules include virtual space, serviced office, hotel or serviced apartment or residential uses. The scenarios are not mutually exclusive. The design principle enables the same space to be used for different uses over time. The transference of a module from one use to another might include: Changing the furniture; possibly the reprogramming or alternation of certain services to suit the requirements of the occupant and the new use of the module. The internal fit-out may consist of a range of standard plug-in modular components providing a variety of functions and forms.
(6) U.S. Patent 4,327,529
This reference is directed to a prefabricated building comprising: a plurality of exterior and interior wall sections joined together in a selected configuration; a plurality of ceiling panels extending between the walls; a plurality of roof trusses overlying the ceiling panels; a roof supported by the trusses. The prefabricated building further comprises a prefabricated utility core comprising: 1) a plurality of vertical connected core walls extending vertically, one of the core walls providing an exterior wall of the building, an access door in this exterior wall, 2) a main sewer line supported in the core and extending through the exterior core wall and having a plurality of lateral sewer lines extending through the core walls, 3) a main water line extending through the exterior core wall and supported in the core and having a plurality of lateral water lines extending through the core walls, 4) a water heater in the core connected to the main water line, 5) a main hot water line connected to the heater and having a plurality of lateral hot water lines extending through the core walls, 6) a breaker box in the core, 7) a plurality of electrical conduits extending from the breaker box; and 8) fixtures utilizing water and discharging sewage connected to selected the appropriate lateral lines.
(7) U.S. Patent 4,655,011 This reference is directed to a prefabricated building system comprising a portable wall unit having a supporting frame and utility apparatus mounted on the supporting frame. The utility apparatus preferably is adjustably mounted on the supporting frame and may comprise plumbing, electrical, heating and/or cooling apparatus for the rooms adjacent to the portable wall unit in the building in which it is to be installed. Prefabricated wall partitions for the adjacent rooms can be assembled with the portable wall unit before shipment to the building site or at the building site. The portable wall unit is provided with means for aligning the wall unit with the adjacent wall partitions to facilitate the assembly thereof. (8) U.S. Patent 5,127,201
This reference is directed to a compact service core structure. The walls of the prefabricated compact service core structure are higher than the total height of the floor, wall and ceiling structure of an ordinary one-story residential building, but lower than the total height of a two-story building of any kind. The height of the walls is large enough to e.g. accommodate the serviced fixtures of complete main floor bathroom, kitchen, and possibly laundry and utility rooms, as well as lower parts of the same rooms of the second story of a two-story structure. On the other hand, the height is small enough to make the prefabricated compact service core structure possible to ship on standard low trailers anywhere in the world. The prefabricated compact service core structure allows for factory completion of all major plumbing, heating, ventilation, and electrical work for a two-story building, and easy on site hook-up to sewer, water, gas and electrical services from the bottom of the prefabricated compact service core structure. Ventilation and possibly electrical services may be extended above the top of the core through one or more extension service panels. As all portions of the floor of both stories and high plumbing wall are suspended, pre-manufacturing of the service core in the plan can easily match all custom designed floor heights or deviations from them usually originating from the supply of building lumber of irregular dimensions.
(9) U.S. Patent 5,890,341 This reference is directed to a modular structure consisting of three modular units of approximately the same size, the center module being the primary module containing the mechanical components of the building, with plumbing, air
conditioning and heating ducts, and electrical wiring in the slab floor structural foundation and door jambs. The primary module used to transport the entire structure is completed at the factory, requiring no further work at jobsite, with heating and cooling unit, hot water heater, cabinets and appliances, plumbing and light fixtures and accessories installed at the factory in permanent locations. The major exterior walls, slab floor foundation panels, and ceiling/roof panels for all three modules are similarly manufactured in one-piece in full width and the length of the building, eliminating joints, speeding assembly and strengthening the components. The major components of the side modules, consisting of the slab floor foundation panels, ceiling/roof panels and the exterior side walls, are all hinged so that they fold to the side and on top of the primary module. Accessories and wall panels and partitions not hinged are placed on top of the primary module for transportation. Two end walls are bolted to the center module during transportation to the site. At the pre- leveled permanent site, the primary module is lowered to the ground and the hinged slab floor foundation panels, which include hinged and folded exterior walls, along with the ceiling/roof panels, are unfolded and permanently fastened in place for that site, but can be refolded if later relocation is needed. The slab floor foundation panels for all three modules are placed directly on the ground or on a pre-built foundation, single or multi-level design. If a pitched roof was ordered, trusses and pre-sized roofing panels transported on top of the primary module are attached to the flat roof of the center module. Two or more of these triple modules can be joined side-to-side or end-to-end or on top of each other, for erection of multiple-unit buildings.
However, none of these inventions allow a house to be built without waiting for installation of infrastructural elements and none of these inventions allow for ease of maintenance or avoidance of damage during remodeling and renovations.
Furthermore, none of these inventions represents an entire house building system - that is from manufacture, through distribution, and installation - with access for maintenance and/or upgrade. What is needed is a way of allowing a house to be built without waiting for installation of services and which, when built, would be easy to maintain and remodel.
Development of a way to allow houses to be built without waiting for installation of services and which, when built, would be easy to maintain and remodel represents a great improvement in the field of construction and satisfies a long felt need of the contractor and homeowner.
Disclosure of Invention
This invention is a core for a building, which has a cuboid framework, at least one story tall, to which all the infrastructural elements for the building are attached. Some of these infrastructural elements are provided with connections for connecting with city services. The elements are so positioned inside the framework that a space is left in the middle for access to all the infrastructural elements. Preferably the framework is made of vertical and horizontal metal beams connected to each other. The framework may be in two halves: a front half-framework and a rear half- framework.
Walls may be attached to the completed core or to each half-core. Depending on where the core will be located in the building, there will either be one exterior wall section and three interior wall sections, or four interior wall sections. One or more of these walls could be shear walls. Alternatively, the completed core or each half-core may be installed in a pre-constructed room in the building.
This invention is also a method of constructing a core for a building, which includes the steps of: connecting vertical and horizontal beams to form a framework of cuboid shape; providing building infrastructural elements, some of which are provided with connections for connecting with city services; attaching a lifting mechanism to the top of the core; and attaching the infrastructural elements inside of the framework in such a way that a space is left in the middle for access to all the infrastructural elements. Alternatively, the completed core or each half-core may be installed in a pre-constructed room in the building. This method may further include the steps of attaching walls, one or more of which may be a shear wall, to the completed core. Preferably the core is placed at an outer edge of the foundation, thus one exterior and three interior walls would be needed. However, the core could be placed inside the building, in which case, four interior walls would be needed. The outsides of the interior wall sections are finished with an interior finish; the outside of the exterior wall section is finished with an exterior finish.
The method may further include the steps of: constructing the core at a location remote from the building site; lifting the core with the lifting mechanism; placing the core on a vehicle; transporting the core to the building site on the vehicle; placing the core on the foundation; and attaching the core to the foundation.
An embodiment of the method of this invention includes the steps of: connecting a front set of vertical and horizontal beams to form a front half-framework of cuboid shape; connecting a rear set of vertical and horizontal beams to form a rear half- framework of cuboid shape; attaching a front lifting mechanism to the top of the front half; attaching a rear lifting mechanism to the top of the rear half; attaching a set of building infrastructural elements inside the front and rear half-frameworks, some of which are provided with connections for connecting with city services, in such a way that a space is left in the middle of each half-core for access to all the infrastructural elements.
This method may further include the steps of: providing a level location remote from the building site; constructing the front and rear half-cores adjacent each other on the level location; testing a least one building infrastructural element; lifting the half- cores with their respective lifting mechanisms; placing the front half-core on a first vehicle; placing the rear half-core on a second vehicle; transporting the half-cores to the building site; placing the half cores on the foundation abutting each other, attaching the half cores to each other; and attaching the competed core to the foundation.
A structural hold down which is used to attach the core to the foundation, is attached to the core at least at each corner. At least one interior platform is provided attached to the inside of at least one of the walls. There may be a means for attaching a floor, external to the core, to each of the interior walls. There is an access door and a fresh air louver in the exterior wall. Water main and gas main connections are provided on the exterior wall, and sewer connections are located inside the core.
A water heater is installed in the core. Clothes washer, drier and dishwasher connections are located in the core, outside of one of the interior wall sections, and as close as possible to the location where each appliance will be in the completed building. Preferably a toilet mechanism is located within at least one of the interior wall sections. This is a special mechanism with a bowl that will be installed later. The mechanism is installed so that the bowl will install from outside of the core. Faucets and mixing valves are attached to the outside of at least one of the interior wall sections. Plumbing and shut off valves interconnect the water main connection, gas main connection, sewer connection, water heater, clothes washer connection, drier connection, dishwasher connection, toilet mechanism, faucet, and mixing valve as necessary and appropriate. The shut off valves are located in the core, adjacent the insides of the interior walls, and as close as possible to the locations where these appliances will be in the completed house, and as close as possible to the interior connections.
An irrigation connection, connected to the water main, is located outside the exterior wall section. An electric mains connection is located on the exterior of the exterior wall section. A subpanel is located within the core and electrically connected to the electric mains connection.
At least one forced air unit is installed within the core. The condenser unit is located outside the core so that hot air produced by the condenser can readily escape. The forced air unit and condenser unit are connected to each other by appropriate ducting. A return air supply duct stub and an air supply duct stub are connected to the forced air unit through one of the interior wall sections.
Phone line and television signal connections are located outside the exterior wall section. The phone line connection is punched down to a punch block within the core. The television signal connection is connected to a signal splitter located inside the core.
A modem is provided inside the core and electrically connected to either the telephone punch block via a DSL line, or to the signal splitter. The modem may be a wired modem, wireless modem or a wired/wireless modem. This invention may include a server within the core.
A security panel is provided inside the core and electrically connected to either the telephone punch block or the modem.
A fire suppression unit is located within the core and connected by a plumbing line to the water main connection. Sprinkler line stubs run from the fire suppression unit through the interior walls of the core.
At least one in-line exhaust fan is provided within the core. Inlet ducts run through interior walls of the core to the in-line exhaust fan, and an outlet duct runs from the fan to the fresh air louver. A control switch is attached to the outside of at least one of the interior wall sections and is electrically connected to the in-line exhaust fan.
A drier vent runs from behind the eventual location of the clothes drier through an interior wall through the core and through the exterior wall.
A range hood is attached to the inside of one of the interior walls over the eventual location of the range. A range in-line exhaust fan could be provided in the core. This would be connected via ducting to the range hood. Alternatively, the fan could be incorporated in the range hood. Exhaust ducting could run from the range inline exhaust fan to the fresh air louver, and control wiring could run from the switch in the range hood to the range in-line exhaust fan.
A core in-line exhaust fan could be located in the core adjacent the fresh air vent, and a thermostatic control could be located inside the core and electrically connected to the core in-line exhaust fan.
This invention may include an internet protocol switching lighting control panel located within the core and electrically connected to the subpanel. This invention may include a water filtration unit in the plumbing between the water main connection and the appliances and the interior connections. This invention may further include a reverse osmosis unit to supply drinking water.
The invention may also include a central vacuum system. This comprises a canister in the core, vacuum outlets in the interior walls, and vacuum tubing interconnecting them.
This invention may also include an interior room within the core. This is formed by attaching an interior floor to the wall sections one story below the tops of the wall sections. This room is preferably a bathroom, which preferably includes another special toilet mechanism installed within at least one of the interior wall sections. This time the mechanism is installed so that the bowl for the toilet will install from inside of the core. The bathroom also includes faucets and mixing valves attached to the inside of at least one of the interior wall sections. Then plumbing and shut off valves are installed to interconnect the appliances in this interior bathroom with the water main connection, the sewer connection, and the water heater as necessary and appropriate; the shut off valves for these appliances being located under the interior floor as close as possible to the appliances.
The present invention is a module that will allow a house to be built without waiting for installation of services. This is because the module is prefabricated with all infrastructural elements already built in. Further, this module allows access to all of the infrastructural elements, thus allowing for ease of maintenance and avoidance of collateral damage during renovations and remodeling. It will be recognized by those familiar with the art to which this invention pertains that this invention could, alternatively, be built on site. The core of this invention separates the infrastructure from the superstructure in a way that allows access to all the infrastructural elements from inside. This is done by prefabricating a module, which contains all the plumbing, mechanical electrical equipment, heating equipment, communications equipment, etc. into one central location that serves the entire house and is easily accessible. This allows the remaining floor plan to be substantially more flexible than traditional floor plans. A central infrastructure core makes distribution much simpler. Plumbing only needs to go a short distance, making repairs and replacements easier, and electrical and mechanical systems also benefit from the location of the core and are able to radiate out into the home in an efficient manner. The house will preferably be wired with smart technology that will allow the lighting and electrical systems to be remotely observed and controlled. Individual web sites will allow home owners to monitor, control and maintain the health of their house from inside or remotely over the internet.
The core has an inherent effect on the architecture of the house in the following ways: 1. The vertical orientation of the core, designed to maximize efficiency in floor space and materials, lends itself to a multi-story home; 2. Because of the consolidation of infrastructure in the core, there are fewer ducts and wires running through the home, resulting in fewer essential walls and fixed floor planes; 3. By using lower ceiling heights, three floors can be provided in a space that would normally accommodate only two floors in a traditional home.
It is an objective of this invention to provide a central core for a house that includes all the functionality of a modern building infrastructural system. Modern infrastructure needs to be upgradeable, interconnected and monitorable. For example, a modern infrastructure should provide notification when FAU filters need to be changed, the water filtration needs filter change, a backup battery for the security system or tech rack needs to be changed, etc. With this invention these devices may be easily changed from within the core.
It is an objective of this invention to provide a core that may contribute to the structural stability of the house. This would be provided by moment frames attached to the core. Alternatively, the moment frames could be incorporated in the framework.
It is an objective of this invention to provide end use plumbing fixtures such as valves, faucets and toilets, already connected to the hot, cold, and sewer distribution systems. This minimizes plumbing time at the site and yields better and more consistent quality work since it is completed in a more controlled environment. It is an objective of this invention to provide 90% of the infrastructural distribution (i.e. pipes, ducts and wires) and 100% infrastructural source hardware (i.e. FAUs, condensers, low voltage controls for lighting or security, water filtration system, electrical panels, fire sprinkler riser, ventilation fans, etc.) within a prefabricated core. This minimizes the work, the time, and the need for many of the trades.
It is an objective of this invention to provide a building in which repair, upgrade or maintenance can be easily and readily accomplished. This would obviate the need to tear up concrete floors, finished ceilings, or finished walls to access a defective solder joint that was leaking. It would also obviate the need to cut into bathroom walls to replace worn out valves. In this invention all hardware is organized and installed so that it is easily accessible. Any aspect of the infrastructure can be updated, maintained, or repaired without touching the finishes. One does not have to open the superstructure or structure to access any aspect of the infrastructure.
It is an objective of this invention to provide the most efficient vertical and horizontal distribution of the infrastructural elements. This invention is equivalent to the crawl space plus attic plus the vertical and horizontal chases and raceways in a traditional building. This invention facilitates the interconnectivity of the modern infrastructural system. For example: the HVAC system needs electricity, hot & cold water, sewer drain, and low voltage control; the security system needs electricity, phone, and network connection; the water heater needs electricity or gas, ventilation, connection to the water mains and connection to the plumbing fixtures; security cameras need electricity, back up batteries, phone system, and access to the network. All of these items and more are provided conveniently and accessibly within the core of this invention. It is an objective of this invention to provide a complete, sophisticated, and ideal infrastructural system to a house while consuming very little time in the construction schedule. It is not only that minimizing the construction time saves money. But also the inherent efficiency of the system plus its factory production will make it cost much less than a site-built house. Further, since the core of this invention is factory built, it is less likely to be built wrongly. The core of this invention will be pretested and thus will be fully functioning at installation. It will be recognized by those familiar with the art to which this invention pertains, that this invention could, alternatively, be built on site.
It is an objective of this invention to provide a core that is sized to be carried on smaller semi-trailers without wide load transport provisions. This invention is light and rigid which makes it easy to transport and install. There are no finishes such as tile or paint that would be vulnerable to damage in shipment.
It is an objective of this invention to provide data on water and electricity consumption, and to operate switches, control temperature, control irrigation system, turn the security system on or off, view the security cameras, and move the shades up and down.
It is an objective of this invention to provide consumer benefits because one company produces the entire infrastructural system. Instead of dealing with multiple subcontractors, customers will deal with the manufacturer of this invention. It is an objective of this invention to provide remote monitoring of many aspects of the health of the infrastructure, through sensors, cameras and internet.
An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and description of a preferred embodiment. An appreciation of the other aims and objectives of the present invention and a more complete and comprehensive understanding of it may be achieved by referring to the accompanying drawings and studying the following description of the best mode of carrying out the invention.
Brief Description of Drawings
Figure 1 is a three-dimensional view of the front half of framework. Figure 1 A is an elevational view of the E side of the framework shown in Figure
1.
Figure 1 B is an elevational view of the S side of the framework shown in Figure 1.
Figure 1C is an elevational view of the N side of the framework shown in Figure
1.
Figure 1 D is an elevational view of the W side of the framework shown in Figure 1.
Figure 2 is a three-dimensional view of the rear half of the framework.
Figure 2A is an elevational view of the E side of the framework shown in Figure
2.
Figure 2B is an elevational view of the W side of the framework shown in Figure 2.
Figure 2C is an elevational view of the N side of the framework shown in Figure
2.
Figure 2D is an elevational view of the S side of the framework shown in Figure
2. Figure 3 is an elevational view of how front and rear frames are positioned for installation of infrastructural elements.
Figure 4 is a three-dimensional view of the front half of framework with the electrical infrastructural element installed.
Figure 4A is an elevational view of the S side of the framework shown in Figure 4.
Figure 4B is an elevational view of the N side of the framework shown in Figure
4.
Figure 4C is an elevational view of the E side of the framework shown in Figure
4. Figure 4D is an elevational view of the W side of the framework shown in Figure 4.
Figure 5 is a three-dimensional view of the front half of framework with the exhaust Infrastructural element installed.
Figure 5A is an elevational view of the N side of the framework shown in Figure 5.
Figure 5B is an elevational view of the E side of the framework shown in Figure
5.
Figure 5C is an elevational view of the S side of the framework shown in Figure
5. Figure 5D is an elevational view of the W side of the framework shown in Figure
5.
Figure 6 is a three-dimensional view of the rear half of framework with the electrical infrastructural element installed.
Figure 6A is an elevational view of the S side of the framework shown in Figure 6.
Figure 6B is an elevational view of the E side of the framework shown in Figure
6.
Figure 6C is an elevational view of the N side of the framework shown in Figure
6. Figure 6D is an elevational view of the W side of the framework shown in Figure
6.
Figure 7 is a three-dimensional view of the rear half of framework with the exhaust infrastructural element installed.
Figure 7A is an elevational view of the N side of the framework shown in Figure 7. Figure 7B is an elevational view of the E side of the framework shown in Figure
7.
Figure 7C is an elevational view of the S side of the framework shown in Figure
7. Figure 7D is an elevational view of the W side of the framework shown in Figure
7.
Figure 8 is a three-dimensional view of the front half of framework with the gas infrastructural element installed.
Figure 8A is an elevational view of the N side of the framework shown in Figure 8.
Figure 8B is an elevational view of the E side of the framework shown in Figure
8.
Figure 8C is an elevational view of the S side of the framework shown in Figure
8. Figure 8D is an elevational view of the W side of the framework shown in Figure
8.
Figure 9 is a three-dimensional view of the rear half of framework with the gas infrastructural element installed.
Figure 9A is an elevational view of the N side of the framework shown in Figure 9.
Figure 9B is an elevational view of the E side of the framework shown in Figure
9.
Figure 9C is an elevational view of the S side of the framework shown in Figure
9. Figure 9D is an elevational view of the W side of the framework shown in Figure 9.
Figure 10 is a three-dimensional view of the front half of framework with the air supply infrastructural element installed.
Figure 10A is an elevational view of the N side of the framework shown in Figure 10.
Figure 10B is an elevational view of the E side of the framework shown in Figure
10.
Figure 10C is an elevational view of the S side of the framework shown in Figure
10. Figure 10D is an elevational view of the W side of the framework shown in Figure
10.
Figure 1 1 is a three-dimensional view of the rear half of framework with the air supply infrastructural element installed.
Figure 1 1 A is an elevational view of the N side of the framework shown in Figure 1 1.
Figure 1 1 B is an elevational view of the E side of the framework shown in Figure
1 1.
Figure 1 1 C is an elevational view of the S side of the framework shown in Figure
1 1. Figure 11 D is an elevational view of the W side of the framework shown in Figure
1 1.
Figure 12 is a three-dimensional view of the front half of framework with the fire suppression infrastructural element installed.
Figure 12A is an elevational view of the N side of the framework shown in Figure 12. Figure 12B is an elevational view of the E side of the framework shown in Figure
12.
Figure 12C is an elevational view of the S side of the framework shown in Figure
12. Figure 12D is an elevational view of the W side of the framework shown in Figure
12.
Figure 13 is a three-dimensional view of the front half of framework with the sewer infrastructural element installed.
Figure 13A is an elevational view of the N side of the framework shown in Figure 13.
Figure 13B is an elevational view of the E side of the framework shown in Figure 13. Figure 13C is an elevational view of the S side of the framework shown in Figure
13.
Figure 13D is an elevational view of the W side of the framework shown in Figure 13.
Figure 14 is a three-dimensional view of the rear half of framework with the sewer infrastructural element installed.
Figure 14A is an elevational view of the N side of the framework shown in Figure
14. Figure 14B is an elevational view of the E side of the framework shown in Figure
14.
Figure 14C is an elevational view of the S side of the framework shown in Figure
14.
Figure 14D is an elevational view of the W side of the framework shown in Figure 14. Figure 15 is a three-dimensional view of the front half of framework with the water infrastructural element installed.
Figure 15A is an elevational view of the N side of the framework shown in Figure
15. Figure 15B is an elevational view of the E side of the framework shown in Figure
15.
Figure 15C is an elevational view of the S side of the framework shown in Figure
15.
Figure 15D is an elevational view of the W side of the framework shown in Figure 15.
Figure 16 is a three-dimensional view of the rear half of framework with the water infrastructural element installed.
Figure 16A is an elevational view of the N side of the framework shown in Figure
16. Figure 16B is an elevational view of the E side of the framework shown in Figure
16.
Figure 16C is an elevational view of the S side of the framework shown in Figure
16.
Figure 16D is an elevational view of the W side of the framework shown in Figure 16.
Figure 17 is a three-dimensional view of the front half of framework with all the infrastructural elements installed.
Figure 17 A is an elevational view of the N side of the framework shown in Figure
17. Figure 17B is an elevational view of the E side of the framework shown in Figure 17.
Figure 17C is an elevational view of the S side of the framework shown in Figure
17.
Figure 17D is an elevational view of the W side of the framework shown in Figure 17.
Figure 18 is a three-dimensional view of the rear half of framework with all the infrastructural elements installed.
Figure 18A is an elevational view of the N side of the framework shown in Figure
18. Figure 18B is an elevational view of the E side of the framework shown in Figure
18.
Figure 18C is an elevational view of the S side of the framework shown in Figure
18.
Figure 18D is an elevational view of the W side of the framework shown in Figure 18.
Figure 19 is an elevational view of the E side of the front and rear half-cores separated but with temporary connections between the infrastructural elements on the two halves for testing.
Figure 20 is a three-dimensional view of front and rear half-cores joined together with all systems installed. The wall panels are omitted to provide a view of all installed systems.
Figure 21 is a three-dimensional view of the front and rear half-cores joined together and exterior panel applied. For clarity only the framework is shown.
Figure 21A is an elevational view from the N side of the assembly shown in Figure 21. Figure 22 is a three-dimensional view of the front and rear half-cores joined together and partially covered with interior and exterior panels or walls installed. For clarity only the framework is shown.
Figure 23 is an elevational view of the front and rear half-cores separated and covered.
Figure 24 is a three-dimensional view of the front and rear half-cores covered and joined. This is how the fully completed core may appear after installation at the job site.
Figure 25 is a three-dimensional view of the bathroom and kitchen joined to the fully assembled core at the building site.
Figure 26 is a three-dimensional cut away view showing aspects of interior panel construction.
Figure 27 is a three-dimensional cut away view showing further aspects of interior panel construction. Figure 28 is a cross-sectional view illustrating construction of an exterior panel.
Figure 29 is a flow diagram describing steps of building a house employing a two-piece core.
Figure 30 is a flow diagram describing steps of building a house employing a one-piece core. Figure 31A is a three-dimensional view of the interior of a fully assembled core at the front of the lower level, looking from the front to the rear of the core.
Figure 31 B is a three-dimensional view of the interior of a fully assembled core midway along the lower level, looking from the front to the rear of the core.
Figure 31 C is a three-dimensional view of the interior of a fully assembled core at the rear of the lower level, looking from the rear to the front of the core. Figure 31 D is a three-dimensional view of the interior of a fully assembled core at the front of the upper level, looking from the front to the rear of the core.
Figure 32A is an elevational view of one typical bathroom layout.
Figure 32A is an elevational view of a second typical bathroom layout. Figure 33 is an elevational view illustrating a moment frame.
Figure 34A is a plan view illustrating one way of locating moment frames in relation to the core.
Figure 34B is a plan view illustrating a second way of locating moment frames in relation to the core. Figure 34C is a plan view illustrating a third way of locating moment frames in relation to the core.
Figure 34D is a plan view illustrating incorporation of moment frames into the core in place of some horizontal and vertical beams.
Figure 34E is a plan view illustrating location of a single moment frame in relation to the core.
Figure 34F is a plan view illustrating incorporation of a single moment frame into the core in place of some horizontal and vertical beams.
Figure 34G is a plan view illustrating another location for incorporation of a single moment frame into the core in place of some horizontal and vertical beams. Figure 35 is a three-dimensional view showing the preferred placement of the horizontal beams and brackets on the front half-frame.
Figure 36 is a three-dimensional view showing the preferred placement of the horizontal beams and brackets on the rear half-frame.
Best Mode for Carrying Out Invention While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
The figures from incorporated US Patent Application Serial No. 12/748,751 illustrate aspects of embodiments of the invention pertaining to the building infrastructure incorporated into the completed core. In the embodiment described in US Patent Application Serial No. 12/748,751 , the prefabricated core is constructed as one unit, and is transported to the building site, as a four-sided room including an exterior panel and three interior panels joined together. The embodiment described in the instant application is an improvement of that described in US Patent Application Serial No. 12/748,751. The three appendices to this application are part of and fully incorporated into this application. In this improvement the core comprises a metal frame inside of which building infrastructural elements are installed in such a way as to leave a space in the middle for access.
In the embodiment described in the instant application, the prefabricated core 174 is constructed at a location remote from the building site, and may be transported to the building site, as two half-cores 11 , 28. At the building site, the two half-cores 11 , 28 are joined together to form the completed core 174. Figures 1 -45 of application No. 12/748,751 illustrate how the infrastructure components are incorporated into the completed core four-sided room. Figures 1-36 of the instant application illustrate aspects of prefabrication of the core 174 in two half-cores 11 , 28. Advantages to constructing the core 174 in two half-cores 11 , 28 include enabling more than one person to install, in parallel, different components of the various infrastructural elements, e.g., electrical and plumbing. Additionally, the sizes of the two half-cores 1 1 , 28 are designed so that transport of the two half-cores 11 , 28 to the building site can be accomplished with standard transportation without the need for wide load carriage. In the instant invention some components need to be connected across the midline 178 between the two half-cores 1 1 , 28. In these cases, connections are made between a component in the front half-core 1 1 and the corresponding component in the rear half-core 28 for testing purposes. After testing, the components are disconnected for transport. Finally, the affected components are reconnected when the two half-cores 11 , 28 are joined at the building site.
Figure 20 illustrates the fully assembled, prefabricated core 174 of this invention. While Figure 20 illustrates a two story core 174, those familiar with the field to which this invention pertains will realize that the core 174 can be one or more stories tall. The exterior grade grating 20c is used for access to the core 174. A ladder may be used to climb up, then access to the interior of the core 174 is through the door 154. See also Figures 21 , 24, 25, and 26.
The completed core 174 may be covered with panels to form a room. If the core 174 is placed abutting an edge of the foundation, these will be one exterior panel 172 and three interior panels 110. If the core 174 is placed within the foundation edges, these will be three interior panels 1 10. In embodiments described in this application, the completed core 174 is constructed of two core half-cores 1 1 , 28. Each half-core 1 1 , 28 of the core 174, described in this application, comprises a cuboid structure having one accessible side 1 12a, 112b. In this context accessible means that no components of any infrastructural element is attached on this side so that people and equipment may pass from the middle space 176a of the front half-core 1 1 to the middle space 176b of the rear half-core. At the job site, the two half-cores 11 , 28 are placed abutting each other, accessible side 1 12a to accessible side 1 12b.
Each half-core 1 1 , 28 of the core 174 may be constructed on a half-framework 10, 26 of vertical 12v and horizontal 12h metal beams. Brackets 22 may be attached at the ends 16 of the horizontal beams 12h. All components are mounted on these half-frameworks 10, 26, and the interior panels 110 and exterior panel 172 may be attached to the brackets 22. The interior panels 1 10 are made of a framework of wood or metal studs 210 covered with interior panel facings 226. The interior panel facings 226 may be plywood or particle board or similar material. Alternatively, the interior panels 110 may be sheet steel. The exterior wall 173 is likewise made of a framework of wood or metal studs 210 covered with an exterior panel facing 236 and coated with an exterior finish 170. The exterior panel facing 236 is, preferably, a polyvinyl chloride composition, or equivalent. The half-cores 1 1 , 28 of this invention are preferably made prefabricated. They are light and rigid which makes them easy to transport. They are sized to be transported on standard semi-trailers without wide load provisions. It will be understood that some or all of the following items will be installed during prefabrication of the half-cores 11 , 28: structural hold downs, platforms 20a, 20b, 20c, an air intake louver 158, a water main connection, a gas main connection, drain pipes 98 and sewer connections, a clothes washer connection 282, a drier connection 306 stove connections 302, a dishwasher connection 294, toilet mechanisms, all faucets 198 and mixing valves, all plumbing and shut off valves, a tankless water heater 106, an outdoor electric meter 30, a subpanel 34, at least one forced air unit, an air conditioner condenser 162, a return air supply duct 86, an air supply duct 82, a phone line connection, a television line connection, a punch block , a signal splitter, a modem, a security panel, a fire suppression unit, sprinkler line and stubs, at least one, replaceable, in-line exhaust fan 54 with inlet and exhaust duct 50 and control switches, a drier vent 150h, a range hood 194 with remote in-line exhaust fan 54 or internal fan, ducting 50 82 86 and associated electrical wiring, and a core in-line exhaust fan 54 with thermostatic control. The condenser 162 sits just outside the core 174, underneath the exterior grade grating 20c. See Figure 25. In this way, the heat generated by the condenser 162 can vent through the grating 20c.
Note that in the Figures, directions (N, S, E and W) are shown for ease of reference to the various sides of the invention. These directions do not imply a direction in which this invention faces.
Figure 1 is a three-dimensional view of the front half 10 of the framework. The half-framework 10 is comprised of beams 12v, 12h. The half-framework 10 is comprised of vertical 12v and horizontal 12h beams attached together so that portions 12p of the horizontal beams 12h protrude past the vertical beams 12v on the E and W sides. Lower, upper, and exterior platforms 20a, 20b (Figure 2), 20c respectively are included, which may comprise one or more gratings 18. In the lower platform 20a, the gratings 18 may be lifted to provide access to components underneath the lower platform 20a. In the upper platform 20b, the gratings are slidably positioned on horizontal beams 12h. The gratings can be slid one way or another to provide access to the components above the upper platform 20b. The space between the lower 20a and exterior 20c platforms and the upper platform 20b comprises a first story 35. The space between the upper platform 20b and the top 56a comprises a second story 37. Thus the lower platform 20a and the exterior platform 20c become the floor of the first story 35 and the upper platform 20b becomes the floor of the second story
Brackets 22 may be attached to the ends 16 of the horizontal beams 12h, on the S, E and W sides of the framework 10. Interior panels 1 10 may be eventually attached to the brackets 22 on the S, E and W sides and an exterior panel 172 may be eventually attached to the N side. See Figure 24. Figure 2 is a three-dimensional view of the rear half 26 of the framework. This is how the half-framework 26 may be fabricated in the factory. The half-framework 26 is comprised of vertical 12v and horizontal 12h beams attached together so that portions 12p of the horizontal beams 12h protrude past the vertical beams 12v on the E and W sides. Lower and upper platforms 20a, 20b are included, which may comprise one or more gratings 18. In the lower platform 20a, the gratings 18 may be lifted to provide access to components underneath the lower platform 20a. In the upper platform 20b, the gratings are slidably positioned on horizontal beams 12h. The gratings can be slid one way or another to provide access to the components above the upper platform 20b. The space between the lower 22a platform and the upper platform 20b comprises a first story 35. The space between the upper platform 20b and the top 56a comprises a second story 37. Thus the lower platform 20a becomes the floor of the first story 35 and the upper platform 20b becomes the floor of the second story.
After the two half cores are joined, the first 35 and second 37 stories in the front and rear halves 11 , 28 are continuous and co-extensive
Brackets 22 may be attached to the ends 16 of the horizontal beams 12h, on the S, E and W sides. Interior panels 1 10 may be eventually attached to the brackets 22 on the S, E and W sides. See Figure 24.
Referring to Figures 35 and 36, the horizontal beams 15h and brackets 22 may be classified as shown in the following tables. Table 1 - Front half
Figure imgf000030_0001
Table 2 - Rear half
Figure imgf000030_0002
Brackets 22 are classified by which way they face: southward 22s, northward 22n, eastward 22e and westward 22w. Brackets face in a particular direction if they can be attached to an element on that side. In other words, a southward facing bracket is positioned so that it can attach to an element on its south side.
Figure 3 is an elevational view from the E side, showing how front 10 and rear 26 frameworks may be positioned for installation of the infrastructural elements.
Figure 4 is a three-dimensional view of the front half of the framework 10 with the electrical infrastructural element installed. Shown are an outdoor electric meter 30, connected to a subpanel 34 by electric wiring (not shown) running through flexible metal conduit 38. Also shown is lifting hook 42 attached to a lifting beam 40, which together comprise the lifting mechanism 44 used to lift the half-framework 10.
Figure 5 is a three-dimensional view of the front half of the framework 10 with the exhaust infrastructural element installed. Shown is exhaust duct 50. Dotted arrows show the direction of air flow. Figure 6 is a three-dimensional view of the rear half of the framework 26 with the electrical infrastructural element installed. Shown are another subpanel 34 and a junction box 46 connected together by flexible metal conduit 38. Also shown is the lifting mechanism 44.
Figure 7 is a three-dimensional view of the rear half of the framework 26 with the exhaust infrastructural element installed. Shown is in-line exhaust fan 54 connected to the exhaust duct 50. Dotted arrows show the direction of air flow.
Figure 8 is a three-dimensional view of the front half of the framework 10 with the gas infrastructural element installed. Shown is gas pipes 58. A dotted arrow shows the direction of gas flow. Figure 9 is a three-dimensional view of the rear half of the framework 26 with the gas infrastructural element installed. This is how the gas system may be installed on the half-framework 26 in the factory. Shown is gas pipe 58.
Figure 10 is a three-dimensional view of the front half of the framework 10 with the air supply infrastructural element installed. Shown are furnace 62, heating coil 66, and furnace vent 64 connected together by a return plenum 70, a first supply plenum 74, and an air supply duct 82. Dotted line arrows show the direction of air flow.
Figure 1 1 is a three-dimensional view of the rear half of the framework 26 with the air supply infrastructural element installed. Shown are second supply plenum 78, third supply plenum 80, air supply ducts 82, and return air supply duct 86 connected together as illustrated. Dotted line arrows show the direction of air flow.
Figure 12 is a three-dimensional view of the front half of the framework 10 with the fire suppression infrastructural element installed. Shown are the fire suppression drain 90, fire sprinkler riser 94 and distribution pipe 96 connected together as illustrated. Dotted line arrows show the direction of water flow.
Figure 13 is a three-dimensional view of the front half of the framework 10 with the drain and sewer infrastructural element installed. Shown are the drain pipes 98, the internal sewer 100, and sewer vent pipe 99 connected together as illustrated. A dotted line arrow shows the direction of air flow in the vent pipe 99.
Figure 14 is a three-dimensional view of the rear half of the framework 26 with the sewer infrastructural element installed. Shown are the drain pipe 98, the internal sewer 100, and sewer vent pipe 99 connected together as illustrated. A dotted line arrow shows the direction of air flow in the vent pipe 99. Figure 15 is a three-dimensional view of the front half of the framework 10 with the water infrastructural element installed. Shown are the cold water influx pipe 102, tankless water heater 106, hot water pipe 103, air inlet 104, and exhaust 108 for combustion gasses. Dotted line arrows show direction of air flow.
Figure 16 is a three-dimensional view of the rear half of the framework 26 with the water infrastructural element installed. Shown is the cold water influx pipe 102 and hot water pipe 103.
Figure 17 is a three-dimensional view of the front half-core 11. It is comprised of the front half-framework 10 with all the infrastructural elements installed. The infrastructural elements are installed on the framework 10 so as to leave a space 176a in the middle. The accessible side 112a is also illustrated. The space 176a and accessible side 112a allow access to all the infrastructural elements for service, repair or replacement.
Figure 18 is a three-dimensional view of the rear half-core 28. It is comprised of the rear half-framework 26 with all the infrastructural elements installed. The infrastructural elements are installed on the framework 26 so as to leave a space 176b in the middle. The accessible side 112b is also illustrated. The space 176b and accessible side 112b allow access to all the infrastructural elements for service, repair or replacement.
Figure 19 is an elevational view of the E side of the front 10 and rear 26 halves of the framework with all infrastructural elements installed, with the front 10 and rear 26 half-frameworks separated but with temporary connection of the infrastructural elements on the two half-cores 11 , 28, for testing. Indicated are temporarily joined exhaust ducts 50, fire suppression drain 90, cold water influx pipe 102, gas pipe 58, and internal sewer 100. As noted earlier, once the two half-cores 1 1 , 28 are tested, the temporary connections are cut.
Figure 20 is a three-dimensional view of the front 11 and rear 28 half-cores joined together with all infrastructural elements installed. Figure 21 is a three-dimensional view of the front 10 and rear 26 half-frameworks joined together and including the exterior wall 173. For clarity only the half-frameworks 10, 26 are shown - i.e. the infrastructural elements are not shown.
Figure 21A is an elevational view from the N (exterior wall) side of the assembly shown in Figure 21. Figure 22 is a three-dimensional view of the front 10 and rear 26 half-frameworks joined together and partially covered. For clarity the infrastructural elements are not shown.
Figure 23 is an elevational view of the E side of the front 1 1 and rear 28 half- cores separated and covered. The coverings may comprise interior panels 1 10 mounted on the half-frameworks 10, 26. This is how the front 1 1 and rear 28 half-cores may appear after completion in the factory, and ready for transport to the building site. Also visible are sections of the flexible metal conduit 38, a junction box 46, an LB box148, a satellite cable conduit 142, and the roof drain 138. Also shown are how the second story ledger 132 and ceiling ledger 136 are installed on the interior panels 110. Figure 24 is a three-dimensional view of the front 11 and rear 28 half-cores covered and joined. This is how the completed core 174 appears after installation at the building site. Shown are conduit for satellite cable 142 and solar panel feed 146, vent covers 150, interior panel 1 10, roof 114, exterior finish 170, ledger boards 132, 136, security camera 152, air intake louver 158, and drier vent 150h. Several positions for the drier vent 150h are shown. These components may be installed during manufacture of the core 174, except for roof 114 which is generally installed at the building site.
Figure 25 is a three-dimensional view of the bathroom 118 and kitchen 122 joined to the fully assembled, prefabricated core 174. Also illustrated are the roof 114, ground floor 126, ceiling of ground floor/floor of second story 130, ceiling of second story 134, access door 154, air intake louver 158, air conditioner condenser 162, city water main 166, exterior wall 173, faucet 198, sink 202, bathtub 204, range hood 194, stove 190. All the illustrated components are installed after the core 174 is installed at the job site. Figure 26 is a three-dimensional cut away view showing aspects of wall construction. The wall could be a shear wall. Elements illustrated are the second story Iedger132, ceiling ledger 136, studs 210, the top plate 214, the interior panel 1 10, the exterior wall 173, the exterior finish 170, the sill 218, and a steel beam 240.
Figure 27 is a three-dimensional cut away view showing further aspects of interior panel 110 construction. Elements illustrated are the studs 210, the top plate 214 and the interior facing 226. North 22n and south 22s facing brackets attach to the N and S sides of the studs 210. The east facing bracket 22e attaches to the W side of a stud 210; and the west facing bracket22w attaches to the E side of a stud. Persons familiar with the art to which this invention pertains will recognize that this construction is typical for interior wall construction in the United States.
Figure 28 is a cross-sectional view illustrating construction of an exterior panel 172. It comprises an exterior facing 236 fastened to studs 210. Further to the exterior is an exterior finish 170 separated from the exterior facing 236 by an air gap 230.
Figure 29 is a flow diagram illustrating the steps of building a house employing a two-piece core 174.
In steps 510 and 520, the two half-frameworks 10, 26 are built. They are then placed next to each other and separated by a small distance on a level sill 218, step 530. Preferably steps 510 through 530 are done at a site remote from the site where the house will be built but could be done at the building site.
In step 540, the infrastructural elements are installed in each half-framework 10, 26. Because components of some infrastructural elements are installed in each half- framework 10, 26, it may be necessary to make temporary connections across the gap, step 550. In step 560, the interior panels 1 10 are attached to the S, E and W sides of the half-frameworks 10, 26 and the exterior wall 173 is attached to the N side of the front half-framework 26. The interior panels 110 and wall 173 can be attached prior to or after the next step, but this the preferred timing. Ledger boards 132, 136 may be attached to the interior panels. Infrastructural elements are tested, step 570. After all infrastructural elements pass testing, the temporary connections are disconnected, step 580.
In step 590 the two half-cores 11 , 28 are lifted, tilted and laid on separate flatbed trucks. They are then trucked to the building site, step 600, where they are lifted of the trucks and tilted upright. The foundation may be laid at the building site at any point in the prior steps but it must be laid prior to placing the half-cores 1 1 , 28 at the building site, step 605.
The half-cores 11 , 28 are placed on the foundation abutting each other, accessible side 1 12a to accessible side 112b with the exterior wall 173 at a location on the foundation that will become the exterior of the house. In steps 630 and 640 the half-cores 11 , 28 are fastened to each other, the half- frameworks 10, 26 are attached to the foundation, and components of infrastructural elements in each half are connected to each other as necessary. After the core 174 is completed, the building is constructed around the core, wet components (see, for example Figure 25) are installed in the proper locations on the core, and utilities (electrical, plumbing, etc.) are run from the core to wherever they are needed in the house, step 650. After this construction proceeds as follows: Erection of prefabricated wall panels for the rest of the house on the foundation.
Openings are left between panels for placement of doors and windows.
Construction of upper floor(s) and ceiling, including connecting floor and ceiling joists to the ledger boards 132, 136 in known fashion.
Installation of windows and doors. Construction of roofing 114 on the top 56 of the core 174 and prefabricated wall panels 110, 172.
Figure 29 is a flow diagram illustrating the steps of building a house employing a one-piece core 174.
In steps 710 and 720, the core framework 8 is built and placed on a level sill 218. Preferably these steps are done at a site remote from the site where the house will be built, but could be done at the building site.
The infrastructural elements are installed in the framework at step 730, and tested at step 740
In step 750, the interior panels 1 10 are attached to the S, E and W sides of the frameworks and the exterior wall 173 is attached to the N side. Ledger boards 132, 136 may also be attached to the interior panels.
In step 760 the core 174 is lifted and laid on a flatbed truck. It is then trucked to the building site, step 770, where it is lifted off the truck, step 780, and placed on the foundation, step 790. The foundation may be laid at the building site at any point in the prior steps but it must be laid prior to placing the core 174 at the building site, step 775. The core 174 is placed on the foundation step 790 with the exterior wall 173 at a location on the foundation that will become the exterior of the house.
In step 800 the framework 8 of the completed core 174 is fastened to the foundation. After the core 174 is installed, the building is constructed around it. Wet components (see, for example Figure 25) are installed in the proper locations on the interior panels, and utilities (electrical, plumbing, etc.) are run from the core 174 to wherever they are needed in the house, step 810. After this, construction proceeds as follows: Erection of prefabricated wall panels for the rest of the house on the foundation.
Openings are left between panels for placement of doors and windows.
Construction of upper floor(s) and ceiling, including connecting floor and ceiling joists to the ledger boards 132, 136 in known fashion.
Installation of windows and doors. Construction of roofing 114 on the top 56 of the core 174 and prefabricated wall panels.
ONE OR TWO-PIECE CORE
One embodiment of this invention is a core 174 for a building, which has a rectangular prism or cuboid shape. For the purposes of this disclosure, "rectangular prism" will be used interchangeably with "cuboid". The dictionary definition of "cuboid" is a "rectangular parallelepiped", which is a box shape. For convenience the sides of the core 174 will be designated throughout this document as N, E, S and W. In no way does this imply the direction in which this invention faces. Preferably the core 174 is built on a framework 8 of vertical 12v and horizontal 12h beams connected to each other as illustrated in Figures 1 and 2. Portions 12p of the horizontal beams 12h protrude past the vertical beams 12v on the E and W sides.
Building infrastructural elements are attached inside of the framework 8 so as to leave a space 176 for access in the middle. Some of these infrastructural elements are provided with connections for connecting with city services, such as water, gas, sewer, phone, cable and electricity. This then is the core 174.
An interior panel 1 10 may be attached to the E, S and W sides and an exterior wall 173 is attached to the N side of the core 174. For the purposes of this application an interior panel 110 is one that is suitable for installation in the interior of a building and an exterior panel 172 is one that is suitable for installation on the exterior of a building. The major difference between these panels is that the exterior panel 172 is constructed to withstand the elements whereas an interior panel 1 10 does not have to be. Persons familiar with the art to which this invention pertains will know the difference in such panels.
The framework 8 may be in two halves: a front half-framework 10 and a rear half- framework 26. The front half-framework 10 includes a front E half-side, a front W half- side and the N side and the rear half-framework 26 includes a rear E half-side, a rear W half-side and the S side. The front S side of the front half-framework 10 and the rear N side of the rear half-framework 26 are open.
TWO-PIECE CORE
A second embodiment of this invention is a core 174 for a building which has a cuboid front half-framework 10, and a cuboid rear half-framework 26. The front half- framework 10 has a front top 56a, front E and W half-sides, and front N and S sides, with the front S side being accessible. The rear half-framework 26 has a rear top 56b, rear E and W half-sides, and rear N and S sides, with the rear N side being accessible. Note that the designations N, E, S, and W are for convenience, and do not imply the direction in which the invention faces. Preferably the half-frameworks 10, 26 are made of vertical 12v and horizontal beams connected to each other as illustrated in Figures 1 and 2. Portions 12p of the horizontal beams 12h protrude past the vertical beams 12v on the E and W sides. Lifting mechanisms 44, comprising a lifting beam 40 and lifting hook 42 are attached to the front top 56a and the rear top 56b.
Building infrastructural elements are attached inside the front 10 and rear 26 half- frameworks, leaving a space 176a, 176b in the middle. Some of these infrastructural elements are provided with connections for connecting with city services, such as water, gas, sewer, phone, cable and electricity.
An interior panel 110 is attached to the front E and W half-sides, the rear E and W half-sides, and the rear S side, and an exterior wall 173 is attached to the front N side of the half-cores 11 26.
METHOD OF FABRICATING A ONE-PIECE CORE
This invention further describes a method of constructing a core 174 for a building, which includes the steps of: connecting vertical 12v and horizontal 12h beams to form a framework 8 of cuboid shape having a top, and N, E, S and W sides with portions 12p of the horizontal beams 12h protruding past the vertical beams 12v; attaching a lifting mechanism 44 to the top; attaching a number of building infrastructural elements inside of the framework 8 so as to leave a space 176 in the middle for access; some of the infrastructural elements being provided with connections for connecting with city services; attaching an interior panel 110 to the E, S and W sides; and attaching an exterior wall 173 to the N side. The method may further include the steps of: pouring a foundation at a building site; constructing the core 174 at a location remote from the building site: lifting the core 174 with the lifting mechanism 44; placing the core 174 on a vehicle; transporting the core 174 to the building site on the vehicle; placing the core 174 on the foundation so that the exterior wall 173 is at an exterior of the building; and attaching the core 174 to the foundation. METHOD OF FABRICATING A TWO-PIECE CORE
An embodiment of this invention describes a method of constructing a core 174 for a building, which includes the steps of: connecting a set of vertical 12v and horizontal 12h beams to form a front half- framework 10 of cuboid shape, as shown on Figures 1 and 2 with portions 12p of the horizontal beams 12h protruding past the vertical beams 12v; connecting a set of vertical 12v and horizontal 12h beams to form a rear half- framework 26 of cuboid shape, with portions 12p of the horizontal beams 12h protruding past the vertical beams 12v; attaching lifting mechanisms 44 to the tops 56a, 56b of the front 10 and rear 26 half- frameworks; attaching building infrastructural elements inside the front 10 and rear 26 half- frameworks 10, 26 so that a space 176a, 176b is left in the middle for access; some of the infrastructural elements being provided with connections for connecting with city services; components of some infrastructural elements being installed in both half- frameworks 10, 26; thus constructing the front and rear half-frameworks 1 1 , 28. attaching interior panels 1 10 to the E and W sides of the front half-core 10 and the E and W and S sides of the rear half-core 26; and attaching an exterior wall 173 to the N side of the front half-framework 10. This produces a front half-core 11 and a rear half-core 28 with coverings 1 10, 172. This method may further include the steps of: pouring a foundation at a building site; providing a level location remote from the building site; constructing the front 1 1 and rear 28 half-cores adjacent each other on a sill on the level location; testing one or more building infrastructural elements as appropriate; lifting the half-cores 11 , 28 with their respective lifting mechanisms 44; placing the front half-core 1 1 on a first vehicle; placing the rear half-core 28 on a second vehicle; transporting the half-cores 1 1 , 28 to the building site; and placing the half-cores 1 1 , 28 on the foundation with the S wall (accessible sidel 12a) of the front half-core 11 abutting the N wall (accessible side 112b) of the rear half-core 28 and the exterior panel 172 at the exterior of the building.
VARIATIONS ON THE ABOVE LISTED APPARATI AND METHODS
Brackets 22 may be attached to the protruding portions 12p. The interior panels 110 may be constructed by attaching studs 210 to interior facings 226. Then the studs 210 of the interior panels 110 may be attached to the brackets 22 on the E and W sides of the front framework 10 and the E and W and S sides of the rear half-framework 26. The exterior panel 172 may be constructed by attaching studs 210 to exterior facings 236. Then the studs 210 of the exterior panel 172 may be attached to the brackets 22 of the N. The studs 210 and facings 236, 226 may be wooden.
A second story ledger 132 may be attached through the interior facings 226 and into the studs 210 on the S, E and W sides at a level to support a floor. A ceiling ledger 136 may be attached through the interior facings 226 and into the studs 210 on the S, E and W sides at a level to support a ceiling 130, 134. City services include water, gas, sewer, phone, cable and electricity.
Preferably, the infrastructural elements include: an electrical infrastructural element (Figures 4,6); an exhaust infrastructural element (Figures 5, 7); a gas infrastructural element (Figures 8, 9); an air supply infrastructural element (Figures 10, 1 1); a fire suppression infrastructural element; a phone infrastructural element; a lighting infrastructural element; a sewer infrastructural element (Figures 13, 14); and a water infrastructural element (Figures 15, 16). The infrastructural elements may further include: a TV distribution infrastructural element; a Wi-Fi infrastructural element; and a water softening infrastructural element. The electrical infrastructural element components may include: an outdoor electric meter 30, connected to subpanels 34, junction boxes 46, and LB boxes 148 by electric wiring (not shown) running through flexible metal conduit 38.
The exhaust infrastructural element may include an in-line exhaust fan 54 and interconnecting ducting 51. The gas infrastructural element may include interconnecting gas pipes 58 with stubs at the ends for connecting the various gas powered appliances.
The air supply infrastructural element may include: a furnace 62; a heating coil 66; a return plenum 70; three supply plenums 74, 78, 80; an air supply duct 82; and a return air supply duct 86 connected together as illustrated on Figures 10 and 11. The fire suppression infrastructural element may include: a fire sprinkler riser 94 connected to connect to a city water main; and a fire suppression drain 90 and distribution pipe 96 connected to the fire sprinkler riser 94. Dotted line arrows show the direction of water flow.
The phone infrastructural element may include: a punch block for connection to a city phone service; a wire connected to the punch block, and adapted to connect to a telephone.
The lighting infrastructural element may include: an internet protocol lighting control panel electrically connected to a subpanel 34. The sewer infrastructural element may include: drain pipes 98, sewer lines'! 00, and sewer vent pipes 99 connected together as illustrated. The drain lines are adapted for attachment to a sink, toilet, shower 340, tub 204, etc. The drain pipes 98 are connected to the internal sewer 100. The water infrastructural element may include: incoming cold water influx pipe
102, tankless water heater 106, hot water pipe 103, air inlet 104, and exhaust 108 for combustion gasses. Dotted line arrows show direction of air flow.
The incoming cold water influx pipe 102, adapted at its front end to connect to a city water main 166, is split into a number of branches and is adapted at the ends of the branches to connect to a cold water appliance such as faucets, toilets, etc. A tankless water heater 106 is also connected to the cold water influx pipe 102 at its inlet and a hot water pipe 103 at its outlet. The hot water pipe 103 is also split into a number of branches and is adapted the ends of the branches to connect to hot water appliance such as faucets, shower heads, etc. The TV distribution infrastructural element may include a coaxial cable to a TV antenna, satellite dish or a city cable TV service.
The Wi-Fi infrastructural element may include a wireless modem connected to a city internet service.
The water softening infrastructural element may include a water softener connected in the water influx pipe 102.
The core 174 according to this invention only provides lateral support to the building. If superior structural support is needed, the core 174 may be attached to or incorporate a moment frame 364. A moment frame 364, or more properly a moment- resisting frame, is a "rectilinear assemblage of beams and columns, with the beams rigidly connected to the columns. Resistance to lateral forces is provided primarily by rigid frame action - that is, by the development of bending moment and shear force in the frame members and joints. By virtue of the rigid beam-column connections, a moment frame cannot displace laterally without bending the beams or columns depending on the geometry of the connection. The bending rigidity and strength of the frame members is therefore the primary source of lateral stiffness and strength for the entire frame." Bruneau, Michel, et al., (2011). Ductile Design of Steel Structures. McGraw-Hill Companies, Inc. ISBN 978-0-07-162395-7. page 347.
A sketch of a moment frame 364 is shown in Figure 33. Moment frames 364 are usually made one horizontal, steel, I beam 368h and two vertical, steel, I beams 368v, welded or fastened together at the corners and connected to or embedded in the foundation 372. In general, moment frames can be designed for each application. In that case the frame must be engineered to meet all structural requirements. However, a number of standard moment frames, which have been pre-engineered to meet all structural requirements are available for purchase. Appendix I of priority document U.S. Patent Application No. 15/298,709 is a catalog of ready-made moment frames and their mechanical properties and incorporated by reference in its entirety.
Moment frames 364 may be placed outside of the core 174 in several locations (see Figures 34A and 34B) or inside the core 174 (see Figure 34C) and then firmly attached to the horizontal 12h and vertical 12v beams of the core 174. Alternatively, moment frames 364 may be incorporated in the core, in place of at least one set of horizontal 12h and vertical 12v beams. See Figure 34D.
Furthermore, one or more moment frames 364 may be used with this invention 174. Figures 34A through 34D illustrate use of two moment frames 364 in association with this invention 174. Instead, depending on exact design and mechanical requirements needed, only one moment frame 364 may be needed. Figures 34E through 34G illustrate use of a single moment frame 364 in association with this invention 174
PROCEDURES AFTER FABRICATION OF CORE The foundation, with sewer connections incorporated in it, is poured on the job site. Then the core 174 is delivered and placed in its proper place on the foundation and secured with the structural hold downs. Construction then proceeds as follows:
Erection of prefabricated wall panels 1 10, 172 for the rest of the house on the foundation. Openings are left in the framing for placement of doors and windows. Construction of upper floor(s) and ceiling, including connecting floor and ceiling joists to the ledger boards 132, 136 in known fashion.
Installation of windows and doors.
Construction of roofing 1 14 on the top 56 of the framing 10, 26.
Running electrical wiring from subpanel 34.
Running alarm system wiring from alarm panel.
Running of phone system wiring from punch block.
Installation of local area network LAN wiring from modem.
Installation of insulation in exterior walls 173.
Attachment of drywall to interior panels 110.
Installation of underlayment for floors 126, 130.
Installation of trim.
Painting.
Installation of finish electrical, such as switches and lights.
Installation of finish alarm system components such as arming panels, magnetic switches and cameras 152.
Installation of LAN and phone system jacks and cover plates.
Installation of all sinks 202.
Installation of bathroom and kitchen counters and cabinets. Installation of faucet decor and toilet bowls. Installation of carpet and other flooring. Hookup to water main or well. Hookup to sewer or septic system. Correction of problems.
It will be understood from the above description that in a house constructed with the core of this invention, the bathrooms, kitchen and laundry room are located next to the outside of an interior panel 172.
The following reference numerals are used on Figures 1 through 36:
8 Complete framework
10 Front half -framework
1 1 Front half of fully assembled, prefabricated core, or front half-core 12h Horizontal beam
12p Protruding portion of horizontal beam. 12v Vertical beam
13a N beam, front half, first story
13b N beam, front half, second story
13c N beam, front half, top
14b Intermediate beam, front half, second story
14c Intermediate beam, front half, top
15a S beam, front half, first story
15b S beam, front half, second story
15c S beam, front half, top 16 End of horizontal beam
17a Beam intermediate N and S sides and intermediate second story and top, front half
17b N beam, intermediate second story and top, front half 18 Grating
20a Interior lower platform with liftable gratings
20b Interior upper platform with slideable gratings
20c Exterior platform with exterior grade gratings
22 Bracket 22s Southward facing bracket
22n Northward facing bracket
22e Eastward facing bracket
22w Westward facing bracket
26 Rear half framework 28 Rear half of fully assembled, prefabricated core, or rear half-core
30 Outdoor electric meter
31a N beam, rear half, first story
31 b N beam, rear half, second story
31c N beam, rear half, top 32a Northerly beam, intermediate N and S sides, rear half, first story
32b Northerly beam, intermediate N and S sides, rear half, second story 32c Northerly beam, intermediate N and S sides, rear half, top
33a Southerly beam, intermediate N and S sides, rear half, first story
33b Southerly beam, intermediate N and S sides, rear half, second story
33c Southerly beam, intermediate N and S sides, rear half, top
34 Subpanel
35 First story
37 Second story
38 Flexible metal conduit
40 Lifting beam
42 Lifting hook
44 Lifting mechanism
46 Junction box
50 Exhaust duct
51 Interconnecting ducting
52 Bathroom, laundry and kitchen hood vents
54 In-line exhaust fan
56 Top of core
56a Top of front half of core
56b Top of rear half of core
58 Gas pipe
62 Furnace Furnace vent
Heating coil
Return plenum
First supply plenum
Second supply plenum
Third supply plenum
Air supply duct
Return air supply duct
Fire suppression drain
Fire sprinkler riser
Distribution pipe
Sewer clean out
Drain pipe
Sewer vent pipe
Internal sewer
Drain connection for connection to e.g. toilet or sink drain. Cold water influx pipe
Hot water pipe
Air inlet
Tankless water heater
Combustion gas exhaust 1 10 Interior panel
1 12b Accessible side of rear half-core
1 12a Accessible side of front half-core
1 14 Roof 1 18 Bathroom
122 Kitchen
126 Ground floor
130 Ceiling of ground floor/floor of second story
132 Second story ledger board 134 Ceiling of second story
136 Ceiling ledger board
138 Roof drain
142 Conduit for satellite cable
146 Conduit for solar panel feed 148 LB box, an electrical L fitting accessible from the rear to facilitate running of wires around 90o bends 50 Vent covers
150a Bathroom
150b Sewer 50d Furnace
150e Kitchen hood 150g Water heater
150h Drier vent (several potential positions shown)
152 Security camera
154 Core access door
156 Roof drain
158 Air intake louver
162 Air conditioner condenser
166 City water main
170 Exterior finish
172 Exterior panel
173 Exterior wall
174 Fully assembled, prefabricated core.
176 Space in middle of fully assembled, prefabricated core.
176a Space in middle of front half-core
176b Space in middle of rear half-core
178 Midline of fully assembled, prefabricated core
190 Stove
194 Range hood
198 Faucet
202 Sink
204 Bathtub 210 Stud
214 Top plate
218 Sill
222 Level surface 226 Interior panel facing
230 Air gap
236 Exterior panel facing
240 Steel beam
244 Mirror backing 248 Vanity backing
252 Roof drain outlet
256 Motion sensor light connection
260 Roof drain overflow
266 Upper cabinet backing 270 Lower cabinet backing
274 Vanity faucet connection
278 Toilet flush plate
282 Water box (hot and cold water connection plus drain) for washing machine. 286 Hot and cold water connections for kitchen faucet
290 Cold water connection for refrigerator 294 Hot water connection for dishwasher
298 Access for remote high and low voltage electrical connections
302 Gas supply for stove
306 Gas supply for dryer
310 Toilet drain
314 Toilet water supply
318 Bathtub hot and cold water connection
322 Shower/bathtub control valve
326 Shower head connection.
340 Shower
344 Toilet
348 Vanity
352 Mirror
356 Laundry chute
360 Showerhead
364 Moment frame
368 I beam
372 Foundation
Construction of this invention 174 will can be found in the priority document, U.S.
Application No. 15/298,709 including its attached Appendix II, incorporated by reference in its entirety. Components used in construction of this invention are listed in Appendix III of priority document U.S. Application No. 15/298,709, incorporated by reference in its entirety.
Thus, the present invention has been described herein with reference to a particular embodiment for a particular application. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof.
It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention.

Claims

Claims
A core for a building comprising: a) a framework of cuboid shape having N, E, S and W sides; said framework comprised of a plurality of vertical and horizontal beams connected to each other; portions of said horizontal beams on said E and W sides protruding past said vertical beams to form E and W protruding portions; whereby said E and W protruding portions have E and W protruding ends; and b) a plurality of building infrastructural elements attached inside of said
framework so that a space is left in the middle for interior access to said infrastructural elements; some of said infrastructural elements provided with connections for connecting with city services.
A core as claimed in claim 1 further comprising a bracket attached to each of said E and W protruding ends on said E and W sides for attachment of a stud of a panel to said W, E and N sides.
A core as claimed in claim 1 in which said framework is comprised of a front half- framework and a rear half-framework; said front half-framework having a front E half-side, a front W half-side, said N side, and a front S side; said front S side being accessible; said rear half-framework having a rear E half-side a rear W half-side, said S side and a rear N side; said rear N side being accessible.
A core as claimed in claim 1 in which said framework includes a moment frame.
A core as claimed in claim 1 in which said city services include water, gas, sewer, phone, cable and electricity.
6. A core for a building comprising: a) a front half-framework of cuboid shape having a front top, front E and W half- sides, S and N sides; said front S side being accessible; b) a rear half-framework of cuboid shape having a rear top, front E and W half- sides, S and N sides; said rear N side being accessible; c) said half-frameworks comprised of a plurality of vertical and horizontal beams connected to each other; portions of said horizontal beams on said E and W sides protruding past said vertical beams to form E and W protruding portions; whereby said E and W protruding portions have E and W protruding ends; and d) a set of building infrastructural elements attached inside said front and rear half-frameworks so that a space is left in an interior middle portion for interior access to said infrastructural elements; some of said infrastructural elements provided with connections for connecting with city services.
7. A core as claimed in claim 6 further comprising a bracket attached each of said E and W protruding ends on said E and W sides for attachment of a stud of a panel to said E, W and N sides.
8. A core as claimed in claim 6 in which said front framework includes a moment frame, said rear half includes a moment frame, or both frameworks include a moment frame.
9. A core as claimed in claim 6 further comprising: a) a front lifting mechanism attached to said front top; and b) a rear lifting mechanism attached to said rear top;
10. A core as claimed in claim 6 in which said city services are water, gas, sewer, phone, cable and electricity.
1 1. A method of constructing a core for a building, comprising the steps of: a) providing a plurality of vertical and horizontal beams; b) connecting said beams so as to form a framework of cuboid shape having a top, and N, E, S and W sides with portions of said horizontal beams on said E and W sides protruding past said vertical beams to form E and W protruding portions; whereby said E and W protruding portions have E and W protruding ends; c) providing a plurality of building infrastructural elements; some of said
infrastructural elements provided with connections for connecting with city services; d) attaching said infrastructural elements inside of said framework so that a space is left inside said core for interior access to said infrastructural elements.
12. A method as claimed in claim 1 1 further comprising the steps of: a) providing brackets for attachment to a stud of a panel; and b) attaching one bracket to each E and W protruding end;
13. A method as claimed in claim 1 1 further comprising the steps of: a) providing a lifting mechanism; and b) attaching said lifting mechanism to said top.
14. A method as claimed in claim 1 1 in which said framework includes a moment frame.
15. A method as claimed in claim 1 1 in which said framework is comprised of a front half-framework and a rear half-framework; said front half-framework having a top, front E and W half-sides said N side and a front S side; said front S side being accessible; said rear half-framework having rear E and W half-sides said S side and a rear N side; said rear N side being accessible.
16. A method as claimed in claim 15 in which said front half-framework includes a moment frame, said rear half-framework includes a moment frame, or each half- framework includes a moment frame.
17. A method as claimed in claim 1 1 in which said city services include water, gas, sewer, phone, cable and electricity.
18. A method of fabricating a core for a building comprising the steps of: a) providing a plurality of vertical and horizontal beams; b) connecting a front set of said beams to form a front half-framework of cuboid shape having a front top, a front E half-side, a front W half-side, a front S side and a front N side; said front S side being accessible; c) connecting a rear set of said beams to form a rear half-framework of cuboid shape having a rear top, a rear E half-side, a rear W half-side, a rear S side and a rear N side; said rear N side being accessible; portions of said horizontal beams on said E and W sides protruding past said vertical beams to form E and W protruding portions; whereby said E and W protruding portions have E and W protruding ends; d) providing a set of building infrastructural elements; some of said
infrastructural elements provided with connections for connecting with city services; and e) attaching said building infrastructural elements inside said front and rear half- frameworks to form a front half-core and a rear half-core; such that a front space is left inside said front half-core for interior access to said
infrastructural elements and a rear space is left inside said rear half-core for interior access to said infrastructural elements.
19. A method as claimed in claim 18 further comprising the steps of: a) providing brackets for attachment of panels to said front and rear half-cores; and b) attaching one bracket to each protruding end.
20. A method as claimed in claim 18 further comprising the steps of: a) providing a front lifting mechanism; b) attaching said front lifting mechanism to said front top; c) providing a rear lifting mechanism; and d) attaching said rear lifting mechanism to said rear top.
21. A method as claimed in claim 18 in which said front half-framework includes a moment frame, said rear half-framework includes a moment frame or each half- framework includes a moment frame.
22. A method as claimed in claim 18 in which said city services are water, gas, sewer, phone, cable and electricity.
23. A method as claimed in claim 18 further comprising the steps of: a) pouring a foundation at a building site; b) testing a least one building subsystem; c) lifting said half cores; d) placing said front half core on a first vehicle; e) placing said rear half core on a second vehicle; f) transporting said half cores to said building site; g) placing said half cores on said foundation so that said rear N side abuts said front S side; h) fastening said half cores to each other to form a core having N, S, E, and W sides; and i) fastening said core to said foundation.
24. A method as claimed in claim 23 further comprising the steps of: a) providing brackets for attachment of panels to said half-cores; and b) attaching one bracket to each protruding end.
25. A method as claimed in claim 24 further comprising the steps of: a) providing six panels; and b) attaching one panel to said front E and W half-sides and said rear E and W half-sides by said brackets; c) attaching a one panel to said N side of said front half-framework; d) attaching one panel to said S side of said rear half-framework.
26. A method as claimed in claim 25 in which said panels are interior panels.
27. A method as claimed in claim 25 in which five of said panels are interior panels and the panel attached to said N side is an exterior panel; said half cores being placed on said foundation so that said exterior panel is located at what will become an exterior of said building.
28. A method as claimed in claim 23 further including the steps of: a) providing a moment frame; b) installing said moment frame on said foundation around or inside said core; and c) structurally attaching said core to said moment frame.
29. A method as claimed in claim 18 further including the steps of: a) providing one or more moment frames; and b) including said moment frame in one half-framework or both half-frameworks.
30. A method as claimed in claim 25 in which at least one of said panels is a shear wall.
PCT/US2017/057449 2016-10-20 2017-10-19 Central core for a building WO2018075802A1 (en)

Applications Claiming Priority (2)

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US15/298,709 2016-10-20

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4655011A (en) * 1984-09-12 1987-04-07 Borges Anthony A Prefabricated building system
US20060277838A1 (en) * 2002-06-07 2006-12-14 Prototype Productions, Inc. Structure having preinstalled utilities and amenities
US20140102019A1 (en) * 2012-10-15 2014-04-17 Stanley Gene Love KE architectural element
US8978324B2 (en) * 2010-06-08 2015-03-17 Innovative Building Technologies, Llc Pre-manufactured utility wall

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4655011A (en) * 1984-09-12 1987-04-07 Borges Anthony A Prefabricated building system
US20060277838A1 (en) * 2002-06-07 2006-12-14 Prototype Productions, Inc. Structure having preinstalled utilities and amenities
US8978324B2 (en) * 2010-06-08 2015-03-17 Innovative Building Technologies, Llc Pre-manufactured utility wall
US20140102019A1 (en) * 2012-10-15 2014-04-17 Stanley Gene Love KE architectural element

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