PREFABRICATED MODULAR GARAGE OR COMMERCIAL CONVERSION ACCESSORY DWELLING UNITS

Abstract

Prefabricated modular accessory dwelling unit kits, methods of converting an interior space into an accessory dwelling unit, and plumbing panel wall assemblies are disclosed. In some embodiments, the prefabricated modular accessory dwelling unit kits include a plumbing panel assembly and a plurality of wall panels. In some embodiments, the methods include attaching a plumbing panel assembly, attaching a plurality of wall panels, and attaching one or more pairs of adjacent wall panels together. In some embodiments, the plumbing panel assembly includes side walls and end walls that collectively define a plumbing panel interior compartment therebetween and a plurality of pipes disposed within the plumbing panel interior compartment.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/150,517 filed on Feb. 17, 2021 and entitled “Workforce Housing,” and U.S. Provisional Patent Application Ser. No. 63/311,030 filed on Feb. 16, 2022 and entitled “Accessory Dwelling Units.” The complete disclosures of the above applications are hereby incorporated by reference for all purposes.

BACKGROUND OF THE DISCLOSURE

The present disclosure is directed to garage or existing commercial use conversion accessory dwelling units, and more particularly to prefabricated modular conversion accessory dwelling unit kits, methods, and various components thereof.

The United States of America and various other countries are in an affordable housing crisis. Housing prices have risen to the point that the working class cannot afford to purchase a home and, in many cases, must commute hours to their employer. Single family and multifamily car garages and underutilized commercially zoned real estate properties provide existing built environments that are underutilized and readily available for reuse to a rentable living units, multigenerational living or seniors a way to age in place with income within the existing communities.

Every garage or commercially zone property is peculiar to itself and can be very time consuming to retrofit to local code requirements with contractors being less sophisticated or reliable on these remodel projects. Ceiling heights width and depth dimensions vary and power and plumbing availability vary as well. Complexity of a code compliant build is compounded by a construction labor shortage making the cost of construction at a premium. It can take months if not years to get permits approved and construction teams to finish a residential build. Many times small or renovation contractors are overbooked and do not show up for work as scheduled. The homeowner or commercial property owner is not a construction expert which heightens the risk of an overpriced capital expenditure that would prohibit profitable economics for building living units for rental use.

What is therefore needed are systems and methods to simplify the conversion of a garage or other interior space into an accessory dwelling unit that is code compliant in the desired state or municipality, which a less skilled labor force can successfully permit and complete. This simplicity will allow less skilled persons to accurately apply for permits and conduct the installation quickly, efficiently, and profitably.

BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS

For a better understanding of the present disclosure, and to show how the same may be carried into effect, reference will now be made, by way of example to the accompanying drawings, which:

FIG. 1 shows a top view of an example of a prefabricated modular conversion accessory dwelling unit, shown without an optional ceiling and associated ceiling box beams.

FIGS. 2-10 show isometric views of an example of a method of assembling the prefabricated modular conversion accessory dwelling unit of FIG. 1.

FIG. 11 shows a top view of another example of a prefabricated modular conversion accessory dwelling unit, shown without an optional ceiling and associated box beams.

FIGS. 12-22 show isometric view of an example of a method of assembling the prefabricated modular conversion accessory dwelling unit of FIG. 11.

FIG. 23 shows an isometric view of an example of adjacent wall panels of the prefabricated modular conversion accessory dwelling units of FIGS. 1 and/or 10, shown with electrical connectors that electrically connect those panels.

FIGS. 24-26 show sectional views of various wall panels of the prefabricated modular conversion accessory dwelling units of FIGS. 1 and/or 11 taken along lines 24-24 in FIG. 23.

FIGS. 27-28 show isometric views of an example of a prefabricated modular plumbing wall assembly of the prefabricated modular conversion accessory dwelling units of FIGS. 1 and/or 11, shown as shipped and prior to installation.

FIG. 29 show a front view of an example of piping within the prefabricated modular plumbing wall assembly of FIGS. 27-28.

FIG. 30 shows a sectional view of a garage or commercial building with the prefabricated modular conversion accessory dwelling unit of FIG. 1 or 11 installed.

FIGS. 31-32 show partial views of the garage or commercial building of FIG. 30 taken along lines 31-31 in FIG. 30.

FIG. 33 shows a flowchart of an example of a method of assembling the prefabricated modular conversion accessory dwelling units of FIGS. 1 and/or 11.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIG. 1, a top view of an example of a prefabricated modular conversion accessory dwelling unit 100 is shown. Unless explicitly excluded, prefabricated modular conversion accessory dwelling unit 100 may include one or more components of other prefabricated modular conversion accessory dwelling units described in the present disclosure. Prefabricated modular conversion accessory dwelling unit 100 has a studio or efficiency layout. The prefabricated modular conversion accessory dwelling unit can be constructed and/or assembled within an interior space or indoor area of a structure, such as a garage, retail, or office building that is attached or detached from a house, a commercial property, a warehouse, etc. The interior space is defined by a floor, a ceiling structure (e.g., rafters, trusses, beams, etc.), and four walls where one or more units can be assembled. In other words, the interior space has a pre-existing floor, a pre-existing ceiling structure, and pre-existing external walls. Additionally, the interior space is adjacent another indoor space or structure (e.g., a house or commercial property) having existing pipes connected to various utilities, such as a water source, a sewer drain, and a vent.

Prefabricated modular accessory dwelling unit 100 includes a wet wall or prefabricated modular plumbing wall assembly 102 and a plurality of wall panels 104 attached to the floor to collectively define one or more rooms 106 therebetween. In some examples, the prefabricated modular plumbing wall assembly also is attached to the ceiling structure and/or one or more external walls. Alternatively, the prefabricated modular plumbing wall assembly is independently supported by its own strength and framing system and is not attached to the existing structure other than being attached to the concrete slab or floor and the adjacent panels and boxbeams. Prefabricated modular plumbing wall assembly 102 includes opposed, spaced, and planar side walls 108 and 110 and opposed, spaced, and planar end walls 112 and 114. End walls 112 and 114 each connect or attached to lateral end portions of side walls 108 and 110 (or are formed together and shipped as a prefabricated modular panel) to collectively define a plumbing panel interior compartment 116 therebetween. Prefabricated modular plumbing wall assembly 102 additionally includes a plurality of pipes 118 and connectors 119 that are at least substantially or completely disposed within the plumbing panel interior compartment and can vary in height based on the existing structure in which it is installed. Each of pipes 118 is attached to side walls 108 and/or 110 and/or end walls 112 and/or 114. Pipes 118 includes one or more sewer pipes, one or more water supply or water pipes, and/or one or more vent pipes. In some examples, pipes 118 also include one or more condensate pipes and one or more dryer exhaust vent and gas pipes.

One or more wall panels 104 are attached to the plumbing wall assembly and/or each other. Wall panels 104 may include structural wall panels 122 and non-structural wall panels 124. Structural wall panels 122 resist twisting and bending and provide more lateral support for the prefabricated modular accessory dwelling unit to support itself independent from the surrounding structure as compared to non-structural wall panels that simply attaches to the existing structure above and beneath the panel requiring no load carrying capacity. Wall panels 104 are described in more detail below. In the example shown in FIG. 1, prefabricated modular accessory dwelling unit 100 includes a mix of prefabricated modular structural wall panels 122 and prefabricated modular non-structural wall panels 124. However, other examples of accessory dwelling unit 100 may include more or less structural wall panels 122 or non-structural wall panels 124. For example, a prefabricated modular accessory dwelling unit 100 may include all non-structural wall panels 124 (and no structural wall panels 122).

In the example shown in FIG. 1, rooms 106 formed by plumbing wall assembly 102 and wall panels 104 include a bathroom 126 and a studio room 128. Bathroom 126 includes a shower 130 having a shower head 132, a sink 134 having a faucet 136, and a toilet 138, which are all adjacent plumbing wall assembly 102. Additionally, studio room 128 includes a kitchen sink 140 having a faucet 142, a stove 143, and a refrigerator/freezer 144, which are all adjacent plumbing wall assembly 102. Although particular orientations and/or sizes of rooms 106 is shown in FIG. 1, other examples of prefabricated modular accessory dwelling unit 100 may include different orientations and/or sizes of rooms 106, and/or more or less rooms 106. For example, bathroom 126 may be positioned along the opposite side wall and/or may be larger or smaller. Similarly, studio room 128 may be larger or smaller.

Referring to FIGS. 2-10, an example of assembling a framework 145 for prefabricated modular accessory dwelling unit 100 is shown. In FIG. 2, wall panels 104 are attached to the floor to provide an exterior wall adjacent the bathroom wet wall. In FIG. 3, a plumbing wall assembly 102 is attached to the floor perpendicular to the previously attached wall panels and also is attached to one of the previously attached wall panels. In some examples, plumbing wall assembly 102 also is attached to the ceiling structure and/or one or more external walls of the interior space. In FIG. 4, wall panels 104 are attached to the floor to provide an exterior back wall. In the example shown in FIG. 4, structural wall panels 122 and non-structural wall panels 124 are attached. However, in other examples, only non-structural wall panels 124 may be attached.

In FIG. 5, additional wall panels 104 are attached to the floor to form the exterior side walls, which meets energy code requirements that a garage or commercial structure may not. In the example shown in FIG. 5, a thinner wall panel 146 is attached to fit the particular sized floor, which is a non-structural wall panel 122 that is created as a flex panel to accommodate the actual area having a smaller width to fit the particular space. In FIG. 6, additional wall panels 104 are attached to the floor to complete the exterior side walls. In the example shown in FIGS. 5-6, structural wall panels 122 (shaded) and non-structural wall panels 124 (non-shaded) are attached. The structural wall panels represent shear walls in a structural stand-alone application. However, in other examples, only non-structural wall panels 124 may be attached. The particular number of structural wall panels 122 used is based on existing conditions and whether the framework must structurally be load carrying.

In FIG. 7, sleepers 148 are attached to the floor and subfloor components 150 are supported on and attached to the sleepers to level the floor, which makes the subfloor compliant to tolerance allowed by code within a living space. The sleepers are sized to ensure that the subfloor formed by the subfloor components is level when installed. The previously attached wall panels 104 are not shown in FIG. 7 to better illustrate the attachment of the sleeper and subfloor components. In other words, the sleepers and subfloor components are attached between the previously attached wall panels and within the rooms formed by those panels. Additionally, only some of the subfloor components 150 are shown to better illustrate the sleepers. However, the subfloor components should completely cover the sleepers.

In FIG. 8, additional wall panels 104 are attached to the floor to form the front wall. Wall panels 104 include end wall panels 152 that are narrower than most of the other wall panels to accommodate the existing garage opening or when a structural system application carries the shear load across the front face of the unit, a window/door panel 154 having a window opening 155 and a door opening 157. In the example shown in FIG. 8, structural wall panels 122 (including end wall panels 152) and non-structural wall panels 124 are attached. However, in other examples, only non-structural wall panels 124 may be attached (including non-structural versions of end wall panels 152). Moreover, in some examples, plumbing wall assembly 102 and/or one or more (or all) of the above wall panels 104 may also be attached to the ceiling structure and/or one or more external walls of the interior space (in addition to being attached to the floor), such as when the prefabricated modular accessory dwelling unit is not carrying its own load.

In FIG. 9, ceiling box beams 158 are attached to top portions of wall panels 104. Pipe extensions 159 may be added to pipes 118 prior to adding ceiling panels 160 to allow fluid access to the pipes after ceiling panels 160 are attached. In FIG. 10, drop in ceiling panels 160 are supported on the ceiling box beams and the top portions of wall panels 104 (on an angle that is attached to the ceiling panels) and are attached on the box beams and/or top portions. One or more ceiling panels may include openings 162 to receive pipe extensions 159 to complete framework 145 of accessory dwelling unit 100. However, in some examples, framework 145 may be completed after FIG. 8 (and before FIGS. 9-10), such as when the prefabricated modular accessory unit 100 is not required to be structurally independent (or carry its own load).

Referring to FIG. 11, a top view of another example of prefabricated modular accessory dwelling unit is generally indicated at 200. Unless explicitly excluded, prefabricated modular accessory dwelling unit 200 may include one or more components of other prefabricated modular accessory dwelling units described in the present disclosure. Unlike prefabricated modular accessory dwelling unit 100, prefabricated modular accessory dwelling unit 200 is a one-bedroom unit. Similar to prefabricated modular accessory dwelling unit 100, prefabricated modular accessory dwelling unit 200 includes a wet wall or prefabricated modular plumbing wall assembly 202 and a plurality of wall panels 104 attached to the floor to define one or more rooms 206 therebetween. In some examples, the plumbing wall assembly and/or the wall panels also are attached to the ceiling structure and/or external wall(s). Prefabricated modular plumbing wall assembly 202 includes opposed, spaced, and planar side walls 208 and 210 and opposed, spaced, and planar end walls 212 and 214. End walls 212 and 214 each connect or attached to lateral end portions of side walls 208 and 210 (or are formed together) to collectively define a plumbing panel interior compartment 216 therebetween.

Plumbing wall assembly 202 additionally includes a plurality of pipes 218 and a plurality of couplers 219 that are at least substantially or completely (fully) disposed within the plumbing panel interior compartment. Each of pipes 218 is attached to side walls 208 and/or 210 and/or end walls 212 and/or 214. Pipes 218 includes one or more sewer pipes, one or more water supply or water pipes, and/or one or more vent pipes. In some examples, pipes 218 also may include one or more condensate pipes one or more gas pipes, and/or one or more dryer exhaust duct.

In addition to attachment to the floor (and optionally the ceiling structure and/or external wall(s) for a non-structural design), one or more wall panels 204 are attached to the plumbing wall assembly and/or each other. Wall panels 204 may include structural wall panels 222 and non-structural wall panels 224. Wall panels 204 are described in detail below. In the example shown in FIG. 11, prefabricated modular accessory dwelling unit 200 includes a mix of structural wall panels 222 and non-structural wall panels 224. However, other examples of accessory dwelling unit 200 may include more or less structural wall panels 222 or non-structural wall panels 224 dependent on the structural design. For example, an accessory dwelling unit 200 may include all non-structural wall panels 224 (and no structural wall panels 222 or a combination thereof).

In the example shown in FIG. 11, rooms 206 formed by plumbing wall assembly 202 and wall panels 204 include a bathroom 226, a bedroom 227, and a great room 228. Bathroom 226 includes a shower 230 having a shower head 232, a sink 234 having a faucet 236, and a toilet 238, which are all adjacent plumbing wall assembly 202. Additionally, studio room 228 includes a kitchen sink 240 having a faucet 142, a stove 243, a refrigerator/freezer 244, and an optional dishwasher and a washer/dryer. The kitchen sink, refrigerator/freezer, and optional dishwasher and washer/dryer are adjacent to plumbing wall assembly 202.

Referring to FIGS. 12-22, an example of assembling a framework 245 for prefabricated modular accessory dwelling unit 200 is shown. In FIG. 12, wall panels 204 are attached to the floor to provide an exterior wall adjacent the bathroom wet wall. In FIG. 13, a plumbing wall assembly 202 is attached to the floor perpendicular to the previously attached wall panels and also is attached to one of the previously attached wall panels. In FIG. 14, wall panels 204 are attached to the floor to provide an exterior back wall. In the example shown in FIGS. 12 and 14, structural wall panels 222 and non-structural wall panels 224 are attached. However, in other examples, only non-structural wall panels 224 may be attached.

In FIG. 15, additional wall panels 104 are attached to the floor to form the exterior side walls. In FIG. 16, additional wall panels 204 are attached to the floor to complete the exterior side walls. In the example shown in FIGS. 15-16, structural wall panels 222 and non-structural wall panels 224 are attached. However, in other examples, only non-structural wall panels 224 may be attached.

In FIG. 17, additional wall panels 204 are attached to the floor to form the front wall. The wall panels include end wall panels 248 that are narrower than most of the other wall panels to accommodate the existing garage door opening or when a structural shear panel of a specific width is required to carry the load on a front face of the prefabricated modular accessory dwelling unit, a window panel 250 having window openings 251 (and that is wider than most of the other wall panels), and a door panel 252 having a window opening 251 and a door opening 253 (and that is wider the most of the other wall panels). In the example shown in FIG. 17, structural wall panels 222 and non-structural wall panels 224 are attached. However, in other examples, only non-structural wall panels 224 may be attached (including non-structural versions of end wall panels 248). In FIG. 18, additional wall panels 204 are attached to the floor to form the internal walls defining the bathroom. The wall panels include an overhead wall panel 254 that is attached to adjacent wall panels 204 (and not the floor) to form an entry point for the bathroom.

In FIG. 19, additional wall panels 204 are attached to the floor to form the internal walls defining the bedroom and great room. The wall panels include an overhead wall panel 256 that is attached to adjacent wall panels 204 (and not the floor) to form an entry point for the bedroom. In some examples, plumbing wall assembly 202 and/or one or more (or all) of wall panels 204 discussed above may also be attached to the ceiling structure and/or one or more external walls of the interior space (in addition to being attached to the floor, if applicable).

In FIG. 20, sleepers 258 are attached to the floor and subfloor components 260 are supported on and attached to the sleepers. The sleepers are sized to ensure that the subfloor formed by the subfloor components is level when installed. The previously attached wall panels 204 are not shown in FIG. 20 to better illustrate the attachment of the sleeper and subfloor components. In other words, the sleepers and subfloor components are attached between the previously attached wall panels and within the rooms formed by those panels. Additionally, only some of the subfloor components 260 are shown to better illustrate the sleepers. However, the subfloor components should completely cover the sleepers.

In FIG. 21, ceiling box beams 262 are attached to top portions of wall panels 204. Pipe extensions 263 may be added to pipes 218 prior to adding ceiling panels 264 to allow fluid access to the pipes after ceiling panels 264 are attached. In FIG. 22, ceiling panels 264 are supported on the ceiling box beams and the top portions of wall panels 204 on a preinstalled angle are attached on the box beams and/or top portions. One or more ceiling panels may include openings 264 to receive portions of pipe extensions 263 to complete framework 245 of prefabricated modular accessory dwelling unit 200. However, in some examples, framework 245 may be completed after FIG. 20 (and before FIGS. 21-22), such as when prefabricated modular accessory dwelling unit 200 is not required to be structurally independent (or carry its own weight).

Referring to FIG. 23, an isometric view of a wall panel 300 (such as wall panel 104 and/or 204) is shown, which is connectable to the plumbing panel assembly and/or other wall panels. Wall panel 300 includes spaced vertical members 302 and spaced horizontal members 304 connecting the ends of the vertical members and defining a frame 306. In some examples, wall panel 300 includes a centrally disposed vertical member 308 (between vertical members 302) and a centrally disposed horizontal member 310 (between horizontal members 304) perpendicularly intersecting each other. Planar side walls 312 are attached on opposed sides 314 and 316 of frame 306 to define a wall panel interior compartment 318 therebetween containing members 308 and 310. Each opposed side may have one or more planar side walls attached to it, as further discussed below. Wall panel 300 may be any suitable size(s). For example, standard wall panels 300 may be four foot wide by eight foot high by a varying depth based on its location, such as 5.125 inches for exterior assembly, 4.625 inches for interior assembly, and for 5.625 inches for structural assembly. However, other wall panels 300 may be any suitable sizes to fit particular spaces and/or to provide door and/or window openings. The centrally disposed vertical and horizontal members may not be included (or excluded) when the wall panels are sized much smaller than the above standard wall panels.

One or more of wall panels 300 may include an electrical assembly 320. The electrical assembly may include at least one electrical switch 322 and at least one electrical outlet 324, which are received in openings 326 and 328 in side wall 312 and are accessible from external wall panel 300. Electrical assembly 320 also includes at least one connector 330 that is positioned external wall panel interior compartment 318 (e.g., on top of frame 306) and/or that is connectable to connectors of the same wall panel and/or other wall panels 300. Suitable examples of connectors 330 includes EZ-Wiring “H-Series” from Electec Building Wiring Systems in Ottawa, Canada. Those connectors are further described in U.S. Pat. Nos. 6,376,770; 6,857,903; and 7,279,635. The complete disclosures of the above patents are hereby incorporated by reference for all purposes.

Electrical assembly 320 further includes a plurality of wiring 332 that electrically connects connector(s) 330 to electrical switch 322 and/or electrical outlet 324 and/or connector 330 with other connectors. Wiring may be at least substantially or completely disposed within wall panel interior compartment 318 and may connect the connector(s) to the switch(es) and/or outlet(s) through openings 334 in members 308 and 310. The wiring that electrically connects connectors 330 may be disposed on top of frame 306 and a trim or panel 336 may be attached adjacent to the top of frame 306 to hide or shield the wiring and the connectors. Although a single electrical switch 322 and a single electrical outlet 324 are shown, each wall panel 300 may include any suitable number of electrical switches and/or electric outlets.

Referring to FIGS. 24-26, various examples of wall panel 300 are shown. In FIG. 24, wall panel 300 includes fiber glass insulation 336 within wall panel interior compartment 318. A drywall 338 (e.g., gypsum drywall) is attached on side 314 of frame 306, while a polyiso insulation wall 340 is attached on side 316 of frame 306. In FIG. 25, wall panel 300 includes the same structure as in FIG. 24 with the addition of a plywood wall or layer 342 disposed between polyiso insulation wall 340 and side 316 of frame 306. In FIG. 26, wall panel 300 includes the same structure as in FIG. 24 except the polyiso insulation wall 340 is replaced with another dry wall 338. The wall panel shown in FIG. 25 may, for example, be used for structural walls 122 and 222, while the wall panel shown in FIGS. 24 and 26 may, for example, be used for non-structural walls 124 and 224. However, other examples of wall panel 300 may alternatively, or additionally, include other walls and/or structures attached to sides 314 and/or 316 of frame 306.

Referring to FIGS. 27-29, a wet wall or prefabricated modular plumbing wall assembly 400 (such as plumbing wall assembly 102 and 202) is shown. Prefabricated modular plumbing wall assembly 400 includes side walls 402 and 404, which are opposed, spaced, and planar. Side walls 402 and 404 includes opposed lateral end portions. Additionally, prefabricated modular plumbing wall assembly 400 includes end walls 406 and 408 that connect side walls 402 and 404 at their lateral end portions. In other words, the end walls connect each adjacent pair of lateral end portions of the side walls to form a plumbing panel interior compartment 414 therebetween. The side walls and end walls are prefabricated and formed together prior to shipping, or may be separate components that are attached to each other prior to shipping. Suitable materials for the side walls and end walls include waterproof and/or mold proof gypsum wall board or exterior plywood.

A plurality of pipes 416 is at least substantially or completely disposed (or contained) within plumbing panel interior compartment 414 and is attached to one or more of the side walls and/or one or more end walls (such as via brackets and/or straps). Pipes 416 includes a sewer pipe 418, a hot water pipe 420, a cold water pipe 422, and a vent pipe 424. In some examples, pipes 416 also includes a condensate pipe, gas pipe, and/or dryer exhaust ducting (not shown). Plumbing wall assembly 400 additionally includes pipe couplers 426 that allow connection of the ends of various pipes 416 to pre-existing pipes connected to a water source, sewer line, or vent. The pipe couplers may be accessed via a top opening 428 or a bottom opening 430 of plumbing panel interior compartment 414, and/or via opening(s) 432 in the side wall(s) and/or end wall(s). For example, the cold water, hot water, and vent couplers may be accessible via top opening 428, and the sewer coupler may be accessible via bottom opening 430. Suitable examples of pipe couplers 426 include various connectors and/or fittings that are approved by Uniform Plumbing Code requirements for each application.

Pipes 416 also includes various fixture couplers 436 that are at least substantially or completely disposed within plumbing panel interior compartment 414 and that are accessible via openings 438 in side walls 402 and 404 to connect the various pipes 416 to various bathroom and/or kitchen fixtures. For example, fixture couplers 436 include a toilet sewer coupler that is fluidly connected to sewer pipe 418 and is connectable to a toilet (e.g., a back outlet toilet), a toilet water coupler that is fluidly connected to cold water pipe 422 and is connectable to the toilet, bathroom sink water couplers and kitchen sink water couplers that are fluidly connected to the hot or cold water pipe 420 and 422 and are connectable to bathroom and kitchen faucet(s), a bathroom sink sewer coupler and a kitchen sink sewer coupler that are fluidly connected to sewer pipe 418 and are connectable to bathroom and kitchen sinks, a shower sewer coupler that is fluidly connected to sewer pipe 418 and is connectable to a shower drain, shower water couplers that are fluidly connected to the hot or cold water pipe and are connectable to a shower head and/or shower faucet(s), a refrigerator/freezer coupler that is fluidly connected to the cold water pipe and is connectable to a refrigerator/freezer, etc. Suitable examples of fixture couplers 436 includes various fittings, such as bell-shaped “female” fittings at top, bottom, and drain locations, in addition to shut off valves for water lines. In some examples, plumbing wall assembly 400 additionally includes an electrical assembly 320, such as discussed for wall panel 300 above.

Referring to FIGS. 30-32, a completed framework 500 (such as framework 145 or 245) of a prefabricated modular accessory dwelling unit (such as accessory dwelling unit 100 or 200) is shown in a garage 600. Wall panels 504 (such as wall panels 104, 204, or 304) of framework 500 (such as framework 145 or 245) is placed adjacent pre-existing external or exterior walls 602 of garage 600. FIGS. 31-32 show various positions of wall panels 504 relative to exterior walls 602. Wall panels 504 are attached to garage floor 604 via floor connectors 506.

Suitable examples of various connectors for used for the framework of the prefabricated modular accessory dwelling units of the present disclosure are described below.

Non-Structural

• • Floor connections: slide angle clips, such as VertiClip® SL by The Steel Network, Inc. Further described in U.S. Pat. Nos. 5,467,566 and 5,906,080, the complete disclosures of which are incorporated by reference for all purposes.
  • Top (ceiling structure) connection @ exterior: coiled straps, such as CS coiled strap manufactured by Simpson; slide angle clips, such as VertiClip® SLD by The Steel Network, Inc.
  • Bulkhead (ceiling structured) connection @ top: angle clips, such as StiffClip® SLD by The Steel Network, Inc.

Structural

1. Box Beam to Wall:

• • 2″ long piece of 362T250-43 track w/ (6) #12 screws through web to top track and (4) #12 screws through each flange to box beam

2. Loose Header Panel to Wall:

• • (2) x track connector per 3/Z500
  • (1) x panel to panel in-line (not corner) connector per 7/Z500

3. Panel to Panel Connections:

• • For in-line connections—6″ long piece of 1½″ leg 54 mil angle w/ (5) #12 screws to each panel
  • For inside-corner connections—2″ long piece of 3″ leg 54 mil angle w/ (7) #12 screws to each panel
  • For outside-corner connections—6″ long piece of 1½″ leg 54 mil angle w/ (6) #12 screws to each panel

4. Shear Wall Hold Down:

• • TSN CL362-118 w/ (4) #12 screws to wall bottom track: angle clips, such as StiffClip® SLD by The Steel Network, Inc.
  • Design Case A Anchor—concrete screw anchors, such as ⅜″ diameter KH-EZ anchor by Hilti
  • Design Case B Anchor—epoxy anchors, such as ½″ diameter threaded rod (F1554 Grade 105) with HIT-RE 500V3 Epoxy by Hilti

5. Typical Wall to Slab:

• • TSN SL362 w/ (2) #12 screws to wall bottom track: slide angle clips, such as VertiClip® SL by The Steel Network, Inc. Further described in U.S. Pat. Nos. 5,467,566 and 5,906,080, the complete disclosures of which are incorporated by reference for all purposes.
  • (2) steel/concrete nails, such as X-U MX steel/concrete nails by Hilti.

6. Ceiling Panel Hold-Down:

• • 2″ long×33 mil strap at each panel corner w/ (1) #12 screw to header or wall stud

7. Hold Downs at Front Shear Walls:

• • (2) hold downs per 9/Z500 each end

Referring to FIG. 34, an example of a method 700 of converting an interior space (defined between a floor, external walls, and a ceiling structure) into an accessory dwelling unit (such as prefabricated modular accessory dwelling unit 100 or 200) is shown. Although particular steps are shown in FIG. 34, other examples of method 700 may omit, replace, modify, duplicate, and/or add one or more steps. Additionally, the steps may be performed in any suitable sequence.

At 702, wall panels are attached to the floor in any suitable orientation, such as parallel to each other. At 704, a plumbing panel assembly is positioned adjacent the attached wall panels (such as perpendicular to the wall panels). At 708, additional wall panels are attached to the floor to form one or more rooms, such as a bathroom, one or more bedrooms, and a living/family room. At 712, sleepers are attached to the floor within the formed rooms. At 714, subfloor panels or components are attached to the sleepers. At 720, electrical connectors of adjacent wall panels are attached together and the electrical system is connected to the pre-existing electrical system. At 722, pipes of the plumbing panel assembly are connected to corresponding pre-existing pipes. For example, the hot and cold water pipes in the plumbing panel assembly are connected to the corresponding hot and cold water pre-existing pipes, the sewer pipe is connected to the corresponding sewer pre-existing pipe, and the vent pipe is connected to the corresponding vent pre-existing pipe. A pump system (e.g., Saniflo system) may additionally be installed outside or in an adjacent room if gravity flow is not possible in the sewer pipe.

Some examples of method 700 may include one or more additional steps. For example, at 706 and 710, the plumbing panel assembly and/or the wall panels are attached to the ceiling structure and/or external walls in addition to being attached to the floor. Additionally, at 716 and 718, ceiling box beams are attached to top portions of the wall panels and/or the plumbing panel assembly and ceiling panels or components are attached to the ceiling box beams.

The present disclosure includes a kit for a prefabricated modular accessory dwelling unit that includes the components described above, such as the plumbing panel assembly, various wall panels, sleepers, subfloor components, ceiling box beams, and/or ceiling components. Because the above components are generally planar (or planar) with any internal components substantially contained inside (and any connectors for those internal components flush or receded from the outside surfaces), the components can be stacked flat in a delivery truck, which facilitates efficient delivery of the kit's components. Installation of the plumbing panel assembly and the wall panels requires, in some examples, fastening of the assembly and panels to the floor and, in some cases, to each other. Electrical connections between panels can be performed by mere coupling or snapping together of the electrical connectors on the top portions of the wall panels having an electrical assembly. Plumbing connections between the plumbing wall assembly and the pre-existing pipes are facilitated by the pipe couplers, while plumbing connections between the plumbing wall assembly and fixtures (e.g., toilet, shower, sinks, etc.) are facilitated by the fixture couplers. When the framework is built, additional fixtures and accessories, such as cabinets, desks, etc., can easily be added.

It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appending claims, as interpreted in accordance with principles of prevailing law, including the doctrine of equivalents or any other principle that enlarges the enforceable scope of a claim beyond its literal scope. Unless the context indicates otherwise, a reference in a claim to the number of instances of an element, be it a reference to one instance or more than one instance, requires at least the stated number of instances of the element but is not intended to exclude from the scope of the claim a structure or method having more instances of that element than stated. Further, the reference numbers, design, and components in the figures are merely illustrative and may be subject to change. The word “comprise” or a derivative thereof, when used in a claim, is used in a nonexclusive sense that is not intended to exclude the presence of other elements or steps in a claimed structure or method.

Claims

1. A prefabricated modular accessory dwelling unit kit, comprising:

a plumbing panel assembly including: opposed, spaced, and planar first and second side walls each having lateral end portions, opposed, spaced, and planar end walls each connecting an adjacent pair of lateral end portions of the first and second side walls, the first and second side walls and end walls collectively defining a plumbing panel interior compartment therebetween, and a plurality of pipes at least substantially disposed within the plumbing panel interior compartment and attached to at least one of the first side wall, second side wall, or one of the end walls; and

a plurality of wall panels each connectable to at least one of the plumbing panel assembly or one or more other wall panels of the plurality of wall panels, each of the plurality of wall panels including: a frame, and planar side walls attached opposed sides of the frame, the frame and planar side walls of the plurality of wall panels collectively defining a wall panel interior compartment therebetween,

wherein two or more wall panels of the plurality of walls panels each having: at least one of an electrical switch or an electrical outlet being received in one or more openings in one of the planar side walls of the two or more of the plurality of wall panels, the at least one of an electrical switch or an electrical outlet being accessible from external the wall panel interior compartment, a connector external the wall panel internal compartment, the connector being connectable to a connector of one or more wall panels of the two or more wall panels, and a plurality of wiring at least substantially disposed within the wall panel interior compartment and electrically connecting the connector and the at least one of an electrical switch or an electrical outlet.

2. The kit of claim 1, wherein the plurality of pipes includes a sewer pipe, a water pipe, and a vent pipe.

3. The kit of claim 2, further comprising a shower head coupler disposed within the plumbing panel interior compartment and accessible external the plumbing panel assembly via a shower head opening of one of the first and second side walls of the plumbing panel assembly, the shower head coupler being fluidly connected to the water pipe.

4. The kit of claim 3, further comprising a kitchen sink water coupler disposed within the plumbing panel interior compartment and accessible external the plumbing panel assembly via a kitchen sink opening of the other of the first and second side walls of the plumbing panel assembly, the kitchen sink water coupler being fluidly connected to the water pipe.

5. The kit of claim 2, further comprising a toilet sewer coupler disposed within the plumbing panel interior compartment and accessible external the plumbing panel assembly via a sewer opening of the one of the first and second side walls, the toilet sewer coupler being fluidly connected to the sewer pipe and fluidly connectable to a back outlet toilet.

6. The kit of claim 5, further comprising a toilet water coupler disposed within the plumbing panel interior compartment and accessible external the plumbing panel assembly via a toilet opening of the one of the first and second side walls, the toilet water coupler fluidly connected to the water pipe and fluidly connectable to the back outlet toilet.

7. The kit of claim 5, further comprising a bathroom sink water coupler disposed within the plumbing panel interior compartment and accessible external the plumbing panel assembly via a bathroom sink water opening of the one of the first and second side walls of the plumbing panel assembly, the bathroom sink water coupler being fluidly connected to the water pipe.

8. The kit of claim 7, further comprising a bathroom sink sewer coupler disposed within the plumbing panel interior compartment and accessible external the plumbing panel assembly via a bathroom sink drain opening the one of the first and second side walls of the plumbing panel assembly, the bathroom sink sewer coupler being fluidly connected to the sewer pipe.

9. The kit of claim 1, wherein one or more wall panels of the plurality of wall panels further includes a vertical member and a horizontal member disposed within the wall panel interior compartment and attached to corresponding portions of the frame.

10. The kit of claim 1, further comprising sleepers and subfloors.

11. The kit of claim 1, further comprising ceiling panels and ceiling box beams.

12. A method of converting an interior space, which is defined between a floor, a ceiling structure, and a plurality of walls, into an accessory dwelling unit, comprising:

attaching a plumbing panel assembly to the floor, the plumbing panel assembly including opposed, spaced, and planar first and second side walls each having lateral end portions, opposed, spaced, and planar end walls each connecting an adjacent pair of lateral end portions of the first and second side walls, the first and second side walls and the end walls collectively defining a plumbing panel interior compartment therebetween, and a plurality of pipes at least substantially disposed within the plumbing panel interior compartment and attached to at least one of the first side wall, the second side wall, or one of the end walls;

attaching a plurality of wall panels to the floor, the plurality of wall panels being adjacent the plumbing panel assembly and forming one or more rooms therebetween, two or more of the plurality of wall panels including: a frame, and planar side walls attached opposed sides of the frame, the frame and side walls of the plurality of wall panels collectively defining a wall panel interior compartment therebetween, at least one of an electrical switch or an electrical outlet being received in one or more openings in one of the planar side walls of the two or more of the plurality of wall panels, the at least one of an electrical switch or an electrical outlet being accessible from external the wall panel interior compartment, a connector external the wall panel internal compartment, the connector being connectable to a connector of one or more wall panels of the two or more wall panels, and

a plurality of wiring at least substantially disposed within the wall panel interior compartment and electrically connecting the connector and the at least one of an electrical switch or an electrical outlet; and

attaching one or more pairs of adjacent wall panels of the plurality of wall panels together.

13. The method of claim 12, further comprising attaching the plumbing panel assembly to one of the ceiling structure or a wall of the plurality of walls.

14. The method of claim 13, further comprising attaching one or more wall panels of the plurality of wall panels to one of the ceiling structure or the plurality of walls.

15. The method of claim 14, further comprising attaching each wall panel of the plurality of walls panels to one of the ceiling structure or a corresponding wall of the plurality of walls.

16. The method of claim 12, further comprising coupling the connectors of each pair of adjacent wall panels that have connectors.

17. The method of claim 12, where the indoor area is adjacent a structure having pre-existing pipes connected to at least one of a water source, a sewer drain, or a vent, further comprising connecting each pipe of the plumbing panel assembly to the corresponding pre-existing pipe.

18. The method of claim 12, further comprising:

attaching a plurality of sleepers to the floor within the one or more rooms; and

attaching a plurality of subfloor components to the plurality of sleepers.

19. The method of claim 12, further comprising:

attaching a plurality of ceiling box beams to top portions of the plurality of wall panels; and

attaching a plurality of ceiling components to the plurality of ceiling box beams.

20. A plumbing panel assembly, comprising

opposed, spaced, and planar first and second side walls each having lateral end portions,

opposed, spaced, and planar end walls each connecting an adjacent pair of lateral end portions of the first and second side walls, the first and second side walls and end walls collectively defining a plumbing panel interior compartment therebetween, and

a plurality of pipes at least substantially disposed within the plumbing panel interior compartment and attached to at least one of the first side wall, second side wall, or one of the end walls.