Modular Dwelling Unit Having Vertically Spaced Zones

Abstract

A modular dwelling is disclosed that includes a dwelling unit, a rectangular base, four exterior walls extending from the base to the roof, and at least one entrance through one of the exterior walls. The dwelling unit also includes a utility zone disposed above the base, a residential zone disposed above the utility zone, a storage zone above the dwelling zone, a mechanical zone above the storage zone, and lifting devices in the mechanical zone adapted to raise and lower furnishings between the storage zone and the dwelling zone. Preferably, the modular dwelling includes multiple dwelling units arranged side by side and/or stacked vertically.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63/371,485 titled “Dwelling Unit Having Vertically Spaced Zones” filed on 15 Aug. 2022, which disclosure is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to dwelling units. More particularly, it relates to a compact, modular dwelling unit with spaces convertible between configurations for different uses. In addition, it relates to modular dwelling units that are adapted to be combined horizontally and vertically into multiple-unit buildings.

BACKGROUND

Open space available for development of new housing is increasingly difficult to find in American cities and in many other cities around the world. In many crowded cities, existing available living space can be very small due to the need to fit more people in the same space. For that reason, it would be of great benefit to design living spaces that provide more functionality in limited living space. For example, much of the space in a conventional home is taken up by bedrooms that are vacant about two thirds of the time. It would be beneficial to be able to adapt these spaces to be more usable during non-sleeping time. The present disclosure addresses designs for dwellings with smaller footprints that have the amenities of larger homes and methods of constructing the same.

SUMMARY

In a first aspect, the disclosure provides a modular dwelling with a dwelling unit. The dwelling unit includes a rectangular base, four exterior walls extending from the base to the roof, and at least one entrance through one of the exterior walls. The dwelling unit also includes a utility zone disposed above the base, a residential zone disposed above the utility zone, a storage zone above the dwelling zone, a mechanical zone above the storage zone, and lifting devices in the mechanical zone adapted to raise and lower furnishings between the storage zone and the dwelling zone.

Preferably, the dwelling includes two or more dwelling units that are placed side by side and/or stacked vertically.

Further aspects and embodiments are provided in the foregoing drawings, detailed description, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are provided to illustrate certain embodiments described herein. The drawings are merely illustrative and are not intended to limit the scope of claimed inventions and are not intended to show every potential feature or embodiment of the claimed inventions. The drawings are not necessarily drawn to scale; in some instances, certain elements of the drawing may be enlarged with respect to other elements of the drawing for purposes of illustration.

FIG. 1 is a perspective view of a first exemplary embodiment of a dwelling unit according to the present disclosure.

FIG. 2 is a perspective view of the embodiment of FIG. 1.

FIG. 3 is a perspective view of three of the embodiments of FIG. 1 combined into a single building.

FIG. 4 is a perspective view of 14 of the embodiments of FIG. 1 combined into a one-story building.

FIG. 5 is a perspective view of the 28 of the embodiments of FIG. 1 combined into a two-story building.

FIG. 6 is a perspective view of the 42 of the embodiments of FIG. 1 combined into a three-story building.

FIG. 6A is a perspective view of several of the three-story buildings of FIG. 6 combined into a larger building.

FIG. 7 is an end plan view showing exemplary examples of four vertical zones in a dwelling according to the present disclosure.

FIG. 8 is a perspective view of an exemplary embodiment of a dwelling unit according to the present disclosure with the walls removed to show an exemplary interior design.

FIG. 8A is a perspective view of several exemplary modules combined into a multi-dwelling building according to the present disclosure.

FIG. 9 is a top plan view of an exemplary embodiment of the lifters in the mechanical zone of the embodiment of FIG. 8.

FIG. 10A is a top plan view of an exemplary embodiment of a dwelling according to the present disclosure.

FIG. 10B is a top plan view of another exemplary embodiment of a dwelling according to the present disclosure.

FIG. 11 is a top plan view of two of the embodiments of FIG. 13A combined to form a single dwelling unit.

FIG. 12A is a top perspective view of the dwelling zone of a second exemplary embodiment of a dwelling having five modules according to the present disclosure.

FIG. 12B is a top perspective view of the embodiment of FIG. 12A reconfigured for sleep.

FIG. 12C is a top perspective view of two of the embodiments of FIG. 12A combined into a single dwelling.

FIG. 12D is a top perspective view of the embodiment of FIG. 12C reconfigured for sleep.

FIG. 13A is a top perspective view of the dwelling zone two of a third exemplary embodiments of a dwelling having four modules and combined into a single dwelling according to the present disclosure.

FIG. 13B is a top perspective view of the embodiment of FIG. 13A reconfigured for sleep.

FIG. 14A is a top perspective view of the dwelling zone of two of a fourth exemplary embodiments of a dwelling having three modules and combined into a single dwelling according to the present disclosure.

FIG. 14B is a top perspective view of the embodiment of FIG. 14A reconfigured for sleep.

FIG. 15A is a top perspective view of the dwelling zone of two of a fifth exemplary embodiments of a dwelling having two modules and combined into a single dwelling according to the present disclosure.

FIG. 15B is a top perspective view of the embodiment of FIG. 15A reconfigured for sleep.

FIG. 16A is cross-sectional partial perspective view of a first exemplary embodiment of a connection system for vertically and horizontally connecting segments of a modular building according to the present disclosure.

FIG. 16B is another cross-sectional view of the embodiment of FIG. 16A.

FIG. 16C is a top perspective view of an exemplary embodiment of a top piece used with the embodiment of FIG. 16A.

FIG. 17 is an exploded perspective view of an exemplary embodiment of a connection system for vertically connecting segments of a modular building according to the present disclosure.

FIG. 17A is a side cross-sectional view of the embodiment of FIG. 17.

FIG. 18 is a side view of the locking pin used in the embodiment of FIG. 17.

FIG. 19 is a perspective view of an exemplary embodiment of the upper pin receiver of FIG. 17.

FIG. 19A is a top view of the embodiment of FIG. 19.

FIG. 19B is a bottom view of the embodiment FIG. 19.

FIG. 19C is a first side cross-sectional view of the embodiment of FIG. 19.

FIG. 19D is a second side cross-sectional view of the embodiment of FIG. 19.

FIG. 19E is a bottom cross-sectional view of the embodiment of FIG. 19.

FIG. 20 is a perspective view of an exemplary embodiment of a lower pin receiver in the embodiment of FIG. 17.

FIG. 20A is a first side cross-sectional view of the embodiment of FIG. 20.

FIG. 20B is a second side cross-sectional view of the embodiment of FIG. 20.

FIG. 20C is a bottom cross-sectional view of the embodiment of FIG. 20.

FIG. 21 is a perspective view of an exemplary embodiment of a locking bolt in the embodiment of FIG. 17.

FIG. 22 is an exploded perspective view of an exemplary embodiment of a system for horizontally joining together four modules or dwelling units according to the present disclosure.

FIG. 23 is a perspective view of the embodiment of FIG. 22.

FIG. 24 is an exploded perspective view of an exemplary embodiment of a system for joining together two modules or dwelling units.

FIG. 25 is an exploded perspective view of the embodiment of FIG. 24.

FIG. 26 is partial perspective view of the embodiment of FIG. 24 for joining two units together vertically.

FIG. 27 is a perspective view of an exemplary embodiment of a floor panel according to the present disclosure.

FIG. 28 is a perspective view of an exemplary embodiment of a wall panel according to the present disclosure.

FIG. 29 is a perspective view of an exemplary embodiment of a female receiver for an exemplary embodiment of a lifter connection according to the present disclosure.

FIG. 30 is a perspective view of exemplary embodiments of a male connector and actuating motor of the lifter connection of FIG. 29.

FIG. 31 is a perspective view of a first exemplary embodiment of a kitchen and utility insert showing the kitchen side according to the present disclosure.

FIG. 32 is a perspective view of a third exemplary embodiment of a kitchen and utility insert showing the utility side according to the present disclosure.

FIG. 33 is a cross-sectional side plan view of an exemplary embodiment of a system for attaching a wire to a cabinet or other fixture to be lowered into the living space according to the present disclosure.

DETAILED DESCRIPTION

The following description recites various aspects and embodiments of the inventions disclosed herein. No particular embodiment is intended to define the scope of the invention. Rather, the embodiments provide non-limiting examples of various compositions, and methods that are included within the scope of the claimed inventions. The description is to be read from the perspective of one of ordinary skill in the art. Therefore, information that is well known to the ordinarily skilled artisan is not necessarily included.

Definitions

The following terms and phrases have the meanings indicated below, unless otherwise provided herein. This disclosure may employ other terms and phrases not expressly defined herein. Such other terms and phrases shall have the meanings that they would possess within the context of this disclosure to those of ordinary skill in the art. In some instances, a term or phrase may be defined in the singular or plural. In such instances, it is understood that any term in the singular may include its plural counterpart and vice versa, unless expressly indicated to the contrary.

As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, reference to “a substituent” encompasses a single substituent as well as two or more substituents, and the like.

As used herein, “for example,” “for instance,” “such as,” or “including” are meant to introduce examples that further clarify more general subject matter. Unless otherwise expressly indicated, such examples are provided only as an aid for understanding embodiments illustrated in the present disclosure and are not meant to be limiting in any fashion. Nor do these phrases indicate any kind of preference for the disclosed embodiment.

As used herein, “panel” is meant to refer to a cuboid of homogenous or non-homogenous material used as at least a partial divider of a space.

As used herein, “track” is meant to refer to a strip of material formed so as to allow movement along a given path in a consistent manner.

As used herein, “track follower” is meant to refer to a small piece of material that is attached to a panel and rides in the track. A track follower keeps the panel material in line with the track and forces the panel to follow the path set by the track as the track follower moves along the track.

As used herein, “divider” is meant to refer to the plurality of panels used to the divide the space.

As used herein, “overhead position” is meant to refer to any space above the space to be divided. Preferably, this space will be above the ceiling, but is not restricted to this.

As used herein, “line” is meant to refer to any device or material that is long, cylindrical, thin, flexible, and having a high tensile strength. Preferably, this will be a braided wire, but ropes, cords, string, twine, cable, strand, chains and combinations thereof may be used as well.

As used herein, “sound dampeners” is meant to refer to a passive material or an active device used to diminish the sound transfer through the divider.

As used herein, “gasket” is meant to refer to any material used to make a seal between two abutting surfaces. Gaskets may also be sound dampeners.

As used herein, “locking mechanism” is meant to refer to any mechanism designed to reversibly hold a plurality of objects together to prevent the dislocation of their current positions.

As used herein, “winch,” “hoist,” “lift,” “winching device,” “hoisting device,” and “lifting device” are meant to refer to an apparatus that can be actuated to selectively raise and lower an object. These terms are generally interchangeable except for where specifically noted herein.

As used herein, “spool” is meant to refer to a generally cylindrical member that rotates to wind a line thereon.

As used herein, “line” is meant to refer to a cable, cord, wire, or other suitable interchangeable generally elongated, flexible, member that winds onto the spool.

As used herein, “fixture” is meant to refer to home furnishings and utilities that are not adapted to be put into storage. Examples of typical fixtures include, but not limited to, sinks, oven/stove, refrigerator/freezer, bath/shower, toilet, and kitchen island. In some embodiments, these examples may be storable and not fixtures.

As used herein, “furniture” is meant to refer to home furnishings that are intended to be placed into the storage. This includes furnishings that are lowered down to floor level or near to floor level to make room for other furniture. Examples of typical furniture include, but are not limited to, tables, seats, couches, beds, dressers, closets, pantries, and exercise equipment. In some embodiments, these examples may be fixtures and not adapted for storage.

As used herein, “furnishings” is meant to refer to both furniture and moveable appliances, such as television screens, exercise equipment, lighting and the like.

Exemplary Embodiments

The present disclosure relates to compact dwelling units for individuals and families. In various exemplary embodiments, the disclosed dwelling units are designed with spaces that can be converted to different uses. For example, sleeping space may be converted into living room, office, exercise, dining, or entertainment space as needed by replacing the bed with other furniture. To accomplish this, the dwelling units include storage space into which furniture may be readily transferred when not in use.

In various exemplary embodiments, the dwelling unit comprises four vertical zones. The primary zone is a dwelling zone in which the residents live. A utility zone located below the dwelling zone holds plumbing, electrical lines, heat and cooling ducts, etc. A storage zone above the dwelling zone provides the storage space to and from which furniture is transferred. Finally, a mechanical zone above the storage zone contains lifting devices used to transfer the furniture.

In various exemplary embodiments, a modular dwelling unit is manufactured in a controlled environment and shipped to the building location for installation. In one embodiment, the unit is shipped in two parts (top two zones and bottom two zones) for safety and to facilitate shipping on roadways with limited vertical clearance (a preferred embodiment is about 14 feet in height).

In various exemplary embodiments, the dwelling units are assembled from one or more modular rooms or modules. Each module has the same dimensions allowing them to be combined to form dwelling units of different sizes. For example, a dwelling unit may comprise two or more modules placed end to end. The standardized size of modules also allows for the assembly of buildings with multiple dwellings by attaching dwellings side-to-side or stacking them top-to-bottom.

In various exemplary embodiments, the dwelling units are designed so that two single units may be combined into a single-family dwelling (referenced herein as a double unit). In various exemplary embodiments, the dwelling units are designed so that two or more units may be combined into a single building with multiple family dwellings (containing single and/or double units). They may be combined horizontally (i.e., a single floor building) and vertically (i.e., a multifloored building). In a preferred embodiment, a multi-unit building may also be built providing common access points, common hallways, and communal spaces.

Referring to FIGS. 1 and 2, a single unit 100 according to the present disclosure is shown installed on the lot of a traditional single family zoned property with a house. In such embodiments, the dwelling may be referred to as an Auxiliary Dwelling Unit or ADU. In various exemplary embodiments, dwelling unit 100 is designed as a standalone unit with all the needed features for its occupants. In a setting such as shown, the dwelling unit would most likely be connected to the primary residence's utility services but those could be provided separately. As shown in FIG. 2, a single unit 100 may be provided with ample open, covered, or partially covered outdoor space for porch furniture and the like.

Referring now to FIG. 3, three of the dwelling units of FIGS. 1 and 2 are combined to form a single multi-family dwelling building 200. In this configuration, each of the dwelling units 100 has an entrance/exit onto a common external porch area. Additional outdoor space, such as shown in FIG. 2 may also be provided. The single dwelling unit 100 includes a floored exterior along at least the end with the entrance which may become an internal hallway in larger combinations of dwelling units, such as shown below in FIGS. 4-6A.

Now referring to FIGS. 4-6A, multiple dwelling units 100 are combined to form a single-story, multi-unit building 200. In the embodiment of FIG. 4, the building comprises a single story with fourteen dwelling units (rotated 90° from the orientation shown in FIGS. 1-3), which may be arranged as single or double units. Such a collection of dwelling units may be referred to as an apartment complex. Internal common hallways (shown with skylights 201) provide access to individual dwelling units. In the illustrated embodiment, a single entrance 202 at the front of the building leads to a first hallway 203 down the length of the building that is crossed by a second hallway 204 that extends the width of the building. In this configuration, the second hallway, which comprises the end porch area of a single dwelling unit, provides access to individual dwelling units in similar fashion to the common porch of FIG. 2.

Referring more specifically to FIG. 5, the fourteen dwelling units are doubled to twenty-eight by placing a second story of fourteen more units directly above the units in FIG. 4. In addition, the front of the building 300 has been expanded to provide common space on each floor for the building occupants. In various exemplary embodiments, an elevator and/or stairs (preferably with a lift for handicapped residents) may be added (e.g., to the end of the first hallway space) to provide access to the upper floor(s).

Now referring to FIG. 6, a third story has been added to the building 300 to bring its size to forty-two dwelling units. Now referring to FIG. 6A, dwelling units like that in FIG. 6 are adjoined into significantly larger buildings for a larger community.

Vertical Zones

In various exemplary embodiments, the modular dwelling unit is divided vertically 100 into four zones: utility 110, residential 120, storage 130, and mechanical 140, from bottom to top. The utility zone contains substantially all the electrical, plumbing, and HVAC ductwork connections for the dwelling unit. The residential zone is designed for human occupancy. The storage zone is adapted to store various furniture pieces (including storage compartments for clothing, food, etc.) when such is not needed in the dwelling zone. The mechanical zone contains the lifters and associated cables and other hardware used to raise and lower the various furniture pieces into and out of the storage zone. In some embodiments, the mechanical zone includes electrical connections to power the lifters, ceiling lights, and to provide power to some furniture (e.g., video screens) when lowered for use.

Now referring to FIG. 7, an exemplary embodiment of the dwelling unit 100 is illustrated. In a preferred embodiment, the vertical dimensions for the zones are utility about 16 inches, living about 95 inches, storage about 48 inches, and mechanical about 9 inches.

Now referring to FIG. 8, an assembled dwelling unit 100 is shown with the walls removed to show the interior. The storage space contains various closets and cabinets and a bed.

Now referring to FIG. 8A, a building assembled from multiple modules 500. Module 500 has a length twice its width, preferably 8.25 feet by 16.5 feet. In such building, the modules may for all or part of a dwelling unit or may be adapted for public use as hallways or gathering spaces (e.g., kitchen, dining room, entertainment rooms, etc.).

Lifters

In preferred embodiments, the furnishings, dividers, and anything else that is intended to be raised or lowered is connected or connectable to a hoisting device comprising a motor, spool, and line. In some embodiments, multiple hoisting devices are used to raise and lower the same object. Useful hoisting devices are disclosed in 63/372,327 titled “Winch with Supporting Rod” filed 23 Aug. 2022; Ser. No. 18/060,532 titled “Winch with Multiple Spools on Single Driveshaft” filed 30 Nov. 2022; Ser. No. 18/060,534 titled “Winch with Helical Groove and Line Guide” filed 30 Nov. 2022; Ser. No. 18/060,536 titled “Winch with Spool and Remote Tensioning Wheel” filed 20 Nov. 2022; Ser. No. 18/060,539 titled “Hoisting Device with Multiple Line Types on Driveshaft” filed 30 Nov. 2022; and Ser. No. 18/060,553 titled “Winch with Line Guide Driven by Wound Line” filed 30 Nov. 2022; each of which are incorporated herein by reference in their entireties.

Now referring to FIG. 9, an exemplary embodiment of a mechanical zone 140 is shown. In a preferred embodiment, hoisting devices 141 are attached to the furniture (not shown) via lines 142 that may pass through one or more pulleys 143. The hoists 141 and pulleys 143 may be placed at different heights to facilitate spacing for more hoists.

Rooms

In various exemplary embodiments, a dwelling unit is constructed from a plurality of modular rooms or modules that are combined to form the dwelling. In other embodiments, the unit is constructed with a single frame subdivided into rooms.

Now referring to FIGS. 10A-B, exemplary embodiments of the dwelling unit are shown. In various exemplary embodiments, the dwelling unit 1100 (or residential zone) contains three basic sections: living 1110, flex 1120, and bathroom 1130. In an exemplary embodiment, the dimensions of the three rooms are 7′ by 10′, 11′ by 10′, and 7′ by 10′.

The residential zone preferably includes at least one module or room adaptable as two or more of a bedroom, living room, dining room, entertainment room, and office, among other possibilities. In various exemplary embodiments, dividing walls may be lowered into place separating one modular room from another.

Now referring to FIG. 11, the flex space includes the kitchen area and may include an oven/stove, dining space, pantry, cabinets, refrigerator/freezer, and a kitchen island and/or desk with built-in seating. In some embodiments, the flex room may also be converted to a sleeping area. In a preferred embodiment, the flex room includes a large sliding wall (or section of the side wall), preferably glass, that may be used as an exit in a single module unit or as a connection between two adjacent modules combined into a single dwelling.

The bathroom includes the bathroom, laundry appliances, and storage above (this may be closets, drawers, or shelves for towels or laundry detergent, etc.). In a preferred embodiment, the utility room also includes a doorway for entry and exit from the module or dwelling unit. As discussed above, when the modules are combined into a multi-unit building, these doors become the primary and often only entrance or exit for the module.

In various preferred embodiments, furnishings that require plumbing connections (e.g., sinks, toilet, shower, washers) are permanent fixtures meaning that they are not raised or lowered into the storage zone. However, they may be designed to be raised or lowered in place based on the needs of the occupants (e.g., for a person in a wheelchair).

In various other embodiments, the dwelling unit may have more or fewer sections. Referring to FIGS. 12A-D, a unit with five sections is shown. From left to right, the modules are a porch, vista room, living room, kitchen, and bathroom/utility room. In these embodiments, all of the modular rooms are 8′ 3″ square, which facilitates making them interchangeable to create different configurations.

Referring to FIG. 12A, the dwelling unit is shown configured for daytime or non-sleep time use. Going from left to right, the units are configured as an outside covered porch or patio, a living room, a dining room, a kitchen, and a bathroom/utility room. In various exemplary embodiments a patio/entry space half the width of the room modules is provided on the right side of the unit. In a preferred embodiment, the room modules are 8′ 3″ wide by 8′ 3″ long.

Referring to FIG. 12B, the dwelling unit of FIG. 12A is reconfigured for night (i.e., for sleeping). The porch is now enclosed and configured with a bed for sleeping. The vista and living rooms are similarly configured.

Referring now to FIG. 12C, the dwelling unit 1100 of FIG. 12A is connected to a mirror image of itself to create a double unit. The same five sections are duplicated on the other side.

Referring now to FIG. 12D, the dwelling unit 1100 of FIG. 12C has dividers 1101 lowered to separate the two halves of the double unit. For sleeping, the units may be converted as shown in FIG. 12B.

Referring now to FIGS. 13A-B, a double unit version of a four-room dwelling unit 1200 is shown. The four sections, from left to right, are a living room, a dining room, a kitchen, and a bathroom/utility room. In this embodiment, the porch/patio is not included. Just as with the embodiment of FIG. 13A, this dwelling unit may be a single unit as well as the double unit shown.

Referring now to FIG. 13B, the daytime configuration of FIG. 13A is converted to a night or sleep configuration. The resident has the option of dividing different sleep spaces or not as desired for couple, children, guests, etc.

Now referring to FIGS. 14A-B, another embodiment is shown. In this embodiment, the dwelling unit 1300 is a double unit and comprises three sections or modules. In the daytime configuration shown in FIG. 14A, there is a dining, kitchen, and bathroom/utility room. In various exemplary embodiments, the dining room may also be converted into a living room or similar space.

The nighttime configuration, shown in FIG. 14B, converts the dining room into bedrooms. As with the other embodiments, this embodiment may be a single or double unit.

Now referring to FIGS. 15A-B, an even smaller embodiment is shown. In this embodiment, there are only two rooms: a kitchen/dining room and the bathroom/utility room.

FIG. 15B shows the same embodiment with the dining space converted into a sleeping space. As with other embodiments, this may be transformed into a double unit.

In alternative embodiments, none of the appliances or furnishings in the kitchen and toilet modules is raised into the storage zone. In these embodiments, the space above the kitchen and toilet may be provided with one or more beds and used as a loft for sleeping.

In various exemplary embodiments, different combinations of the five sections shown in FIGS. 12A-D may be combined into other combinations, which may include any number of sections including duplicate sections in the same unit. In preferred embodiments, the kitchen with dining and sleeping capability and the bathroom with utility are considered the minimum necessary for a dwelling. In various exemplary embodiments, the unit includes an “open” space outside the entrance to the unit that is half the width of a module. For a single or small number of units together, this may provide a patio space. When the units are combined into a building with multiple units, this space becomes a hallway providing access to units. The units are preferably arranged so that the hallway is the width of a single module by connecting units such that two hallways are combined with entrances across the hallway. In various exemplary embodiments, a utility box with circuit breakers, water main valve, etc. is located in or accessible from the hallway/entry space.

In various exemplary embodiments, room modules are constructed using a common frame design comprising stainless steel. In various exemplary embodiments, modules are attached together horizontally using a system like that described in more detail below. The same type of system may be used to connect one unit to another. In various exemplary embodiments the modular room frames include the dwelling zone and the utility zone. In such embodiments, the storage and mechanical zones are assembled and shipped separately and are placed on top of the dwelling zone after it is shipped and installed on a foundation.

Construction Methods

In various exemplary embodiments, the modular dwelling unit is constructed with a steel frame to which sidewalls, roofs, ceilings floors, foundations, etc. are attached. In various exemplary embodiments, individual room modules comprising the utility and dwelling zones and another for the storage and mechanical zones are assembled individually and then are joined together horizontally for shipment to the building site. The assembled lower modules are installed on the site and the upper assembled modules are then installed on top of that.

Pilings and Building Connections

In various exemplary embodiments, the dwelling units are installed on a concrete foundation or slab supporting a plurality of pilings. In other embodiments, the dwelling units are supported on pilings without a cement foundation. In preferred embodiments, the pilings are configured such that there is a piling at each corner of a modular room or module. In such an embodiment, the number of pilings depends on the number of modules/rooms in the unit. In a preferred embodiment, the dwelling may be provided with decking adapted to be placed on an end or side of the unit that is the same dimensions as the modular rooms and uses the same piling system. This facilitates the replacement of decks with adjoined units in the event a unit or complex of multiple units is to be expanded.

Accurate placement of pilings is notoriously difficult. In order to address this problem, the connection to the piling attachment system is adapted for adjustment in any direction in the horizontal plane. Bolts connecting the pilings and building pass through slots rather than holes allowing the connecting pieces to slide relative to the bolt. By putting perpendicular slots in top and bottom components, full direction of movement is provided.

In various exemplary embodiments, multiple floors are assembled by locking the bottom of one unit to the top of another unit. In a preferred embodiment, each module is adapted to include a locking mechanism at each corner in the same pattern as the pilings. In various exemplary embodiments, the system for connecting one floor to another above or below is similar to the system for placing the first floor on the pilings. In various exemplary embodiments, the locking mechanism also is used to connect individual units to adjacent units on the same floor as well. Because the modules are preferably assembled off-site, it is important that the locking mechanism be designed for easy connection when lowering one module on top of another.

Now referring to FIGS. 16A-C, an embodiment of a system 400 for vertically and horizontally connecting building sections is shown. The system 400 may be used to connect the bottom of a unit to a foundation or piling, to connect one unit on top of another, or to connect one zone to another within a unit. The system also functions as a horizontal connection between modules in a unit or between adjacent units.

Still referring to FIG. 16A, an upper piece 401 and lower piece 402 are connected by a frustoconical sleeve 403. The frustoconical shape is preferred to make it easier to align and attach components vertically. A bolt (not shown) is passed through the sleeve and connected to a nut (not shown) in the bottom piece.

Referring to FIGS. 16A-B, a horizontal connector 410 is attached to the bottom piece 402 of one module or unit and extends over to an adjacent module unit. It is locked in place with one or more bolts (not shown).

Now referring to FIG. 16C, an embodiment of a cap piece 420 is shown. For the top of the unit, or top of units on the top floor, a different top piece is utilized. This piece is not designed to connect with a unit above but only horizontally. It can be shaped to connect four units or modules, as shown in FIG. 16C, or adapted to connect two units or modules.

Now referring to FIGS. 17 and 17A, another embodiment of a system for vertically connecting building sections is shown. As with the prior embodiment, the system may be used to connect the bottom of a unit to a foundation or piling, to connect one unit on top of another, or to connect one zone to another within a unit.

Still referring to FIGS. 17 and 17A, an exemplary embodiment of a pinning mechanism 430 is shown. The locking mechanism 430 comprises a bottom pin receiver 431, a locking pin(s) 432, a top pin receiver 433, and a locking bolt 434. In various exemplary embodiments, the lower receiver 431 is attached to or built into the top of a module. Similarly, the upper pin receiver 433 is attached to or built into the bottom of a module.

Now referring to FIG. 18, an exemplary embodiment of a locking pin 432 is shown. In a preferred embodiment, the locking pin 432 is cylindrical which permits it to fit into the receivers regardless of rotational position. The locking pin 432 comprises a tapered tip 435 to facilitate connecting modules. The locking pin 432 further comprises an annular groove 436. In a preferred embodiment, the top of the locking pin 432 is threaded for connection to the male pin receiver. In such embodiments, it is also adapted for easy installation with a pair of flattened surfaces for interaction with a wrench or similar tool for threading into the male pin receiver.

Now referring to FIGS. 19-19E, an exemplary embodiment of a top pin receiver 433 is shown. In various exemplary embodiments, a top pin receiver 433 is connected to each bottom corner of a module. In a preferred embodiment, the top pin receiver is secured to the module by one or more bolts or other connectors (not shown) via bolt holes 437. In other embodiments, it may be welded to the module or may be an integral part of it.

Now referring to FIGS. 20-20C, an exemplary embodiment of a bottom pin receiver 431 is shown. In various exemplary embodiments, the lower receiver is part of the module. The bottom pin receiver 431 comprises a circular receiving slot 438 with a tapered section adapted to receive the locking pin 432. The lower receiver also includes one or more threaded locking bolt holes 439 adapted to receive the locking bolt. After the locking pin is inserted into the lower receiver, it is locked in place by inserting locking bolt 434 (see FIG. 21) into the receiver where it engages with the annular groove 436 of the locking pin 432.

Now referring to FIG. 21, an exemplary embodiment of a locking bolt 434 is shown. In various exemplary embodiments, the locking bolt is threaded near its head. Only this portion needs to be threaded to lock the bolt in place.

Now referring to FIGS. 22-23, an exemplary embodiment of another system 600 for connecting modules and dwelling units is shown. Adjacent modules are attached horizontally by plate 610. Plate 610 is attached to the modules by bolts 611. The plates are also secured by vertical pins 620, which are also used to join modules vertically.

Now referring to FIGS. 24-25, another exemplary embodiment of the connecting system is shown. In this embodiment, plate 610 is adapted to connect two modules rather than 4. A second plate 630 is secured by screws, bolts, or other connectors to the sides of the module walls.

Now referring to FIG. 26, an exemplary embodiment of a system for vertically connecting modules is shown. Locking pin 620 is connected to the lower module via a hole, preferably with a threaded connection. Locking pin 620 has a frustoconical top to facilitate lowering the upper module onto it.

Floors and Walls

In various exemplary embodiments, the dwelling is designed such that single units can be combined into large, multi-family dwellings. Because the exterior walls of many such units will be on the interior of a larger building, they are inaccessible from outside the unit. Similarly, the utility, storage, and mechanical zones are inaccessible from outside the unit. Therefore, these spaces are installed and accessible for maintenance or repair from the interior of the dwelling. For this reason, the dwelling is designed with a plurality of removable wall and floor panels allowing access to the utility zone and to the inside of walls. In various exemplary embodiments, outside walls may be covered with a variety of facades such as are used in conventional buildings.

Now referring to FIG. 22, an exemplary embodiment of a floor panel 440 is shown. In preferred embodiments, floor panel 440 comprises two rigid panels 441, preferably made from fiber-reinforced polymer (FRP), sandwiched around a layer of insulation 442. In one embodiment, the floor panel 440 comprises Formica sheets and foam insulation 442. In some embodiments, the insulation comprises expanded polystyrene (XPS) foam.

Now referring to FIGS. 23-23A, an exemplary embodiment of a wall panel 450 is shown. In preferred embodiments, wall panel 450 comprises two rigid panels 451, preferably made from fiber-reinforced polymer (FRP) or stainless steel, sandwiched around a layer of insulation 452. In one embodiment, wall panel 450 comprises an interior panel made of Formica, an insulated layer comprising a vacuum panel such as used in refrigeration, and an outer wall panel made from stainless steel. In other embodiments, the insulation comprises expanded polystyrene (XPS) foam. In some embodiments, the layers are attached using two-sided tape such as that produced by 3M Corporation. In a preferred embodiment (depicted in FIG. 23A), the panel 450 comprises (from top to bottom as shown) G10 fiberglass, foam, G10 fiberglass, and VHB tape.

In various exemplary embodiments, the preferred rigid panels for floor or wall panels comprise, for example, a stiff layer of G10 fiberglass (0.030″-0.090″), Formica, FRP, or plastic, etc. glued to the Extruded Polystyrene (XPS) Rigid Foam (example Owens Corning FOAMULAR 150 1 in.×4 ft.×8 ft. R-5) and on the opposing side another stiff layer of material like G10 fiberglass (0.030″-0.090″), Formica, FRP (fiber reinforced plastic), or plastic, etc. glued to the foam on that side. The stiff layer of material can be glued onto the foam with various gluing methods (i.e., hot melt plastic glues, epoxies, contact cement, construction glues etc.). Once the stiff layers are glued onto the XPS foam the member becomes a composite member having significant more strength than the foam by itself or the stiff members by themselves. This composite material offers many advantages since it has insulating properties it can be used in flooring and, in some configurations, it is strong enough to be used as the sub-floor that can be walked on and furniture placed on. It can also be used in walls and ceilings as well as an insulative outer layer to protect the building.

Other material can be used instead of foam materials for the interior of the composite panels. In various exemplary embodiments, the insulation for the interior of floor and wall panels comprises foams such as discussed above or vacuum insulated panels (VIP). VIP panels allow for much better insulation than the foam materials that are available.

Examples of composites appropriate for floor and/or wall panels include, but are not limited to, Formica or Formica like materials on both sides of an XPS foam; G10 or fiberglass like materials on both sides of an XPS foam; Graphite fiber sheets, Kevlar, or other fiber composite type sheets glued to both sides of the XPS foam; fiber reinforced plastic (FRP) or similar type materials glued to both sides of the SPX foam; and plastic layers like polyethylene, acetal, nylon, PVC, polycarbonate, acrylic, polypropylene, PTFE, etc. again glued to the XPS foam. Fiber reinforced plastics, rubbers, or fiber reinforced rubbers can also be used.

Raisable Doors, Walls, and Windows

In various exemplary embodiments, it may be desirable to separate part of a dwelling from another, for purposes such as providing privacy or noise reduction. In embodiments where two units are combined to form a larger unit, doorways between the units are needed. It may also be desirable to remove or add walls between the units, such as to create open space or provide private space (e.g., for sleeping, etc.) as needed. Exemplary apparatus and systems for this purpose are disclosed in U.S. Pat. No. 11,359,372 titled “Systems for Reversibly Dividing a Space” filed on 20 Jun. 2019 now and U.S. patent application Ser. No. 17/806,779, published as US 2022-0307260, and titled “System for Reversibly Dividing a Space” filed on 14 Jun. 2022, the disclosures of which are included herein in their entireties by reference.

Locking Mechanism

Cables provide an efficient and effective medium for raising and lowering features but having cables extending from the top of a component such as a couch or table up to the ceiling is unsightly, an obstacle, and poses potential danger. For those reasons, various exemplary embodiments include a system for raising and lowering components that does not require a permanent connection to the component. Rather the lifting mechanism may be detached from the component and raised back into the storage space above the ceiling.

Referring now to FIG. 24, an exemplary embodiment of a female receiver 460 adapted for use in a component is shown. The receiver includes a central opening 461 into which a connector may be lowered. It further includes one or two channels 462 for receiving locking pins.

Now referring to FIG. 25, an exemplary embodiment of a connector 463 and motor 464 are shown. In one preferred embodiment, the connector includes a rod 465 with two locking pins 466 extending from opposite sides. The rod 465 is adapted for insertion into the receiver opening 461 with the pins 466 entering the channels 462. When the rod is inserted, the rod may be rotated such that the locking pins engage with the channels such that when the rod is lifted, the locking pins engage with the top of the channel and lift the receiver and connected component with it. When the component is lowered to the floor, the rod is rotated to disengage the pins with the channel allowing the rod to be raised back into the storage zone. In various exemplary embodiments, the rod is part of a component or other mechanism that is raised and lowered with cables as described above.

Roof

In various exemplary embodiments, the roof is designed to collect and drain water, whether from natural sources or a leak from a unit above. The modules have roof sections that function much like a tub to collect water, direct it to a drain, and dispose of the water. Water may be discharged outside the building, into sewage drains, or stored for later use (e.g., irrigation).

Fixtures and Furniture

In various exemplary embodiments, some kitchen and bathroom/utility room features are built separately and placed in the building frame after assembly. FIGS. 26-27 show an exemplary embodiment of such a construct that includes an over/stove top, kitchen sink, and refrigerator/freezer on one side and a bathroom sink and space for stacked washer/dryer on the other side. In some embodiments, the kitchen fixtures are height adjustable to accommodate occupants of varying heights and the handicapped.

Now referring to FIG. 26, an embodiment of a construct with kitchen fixtures. The module includes a sink, oven, stove, and a small counter space. The kitchen module may include an island/table with more storage and counter space. The construct also includes refrigerator/freezer space above the sink and oven. In various exemplary embodiments, pantry space is provided by storage units kept in the storage zone above the kitchen when not being accessed by the occupants.

Now referring to FIG. 27, the opposite side of the assembly is shown. The bathroom side of the assembly includes a sink and space for a stacking washer and dryer. The panel above the sink is preferably hinged to allow access to and/or viewing of wiring, plumbing, etc. in the interior of the assembly.

In various exemplary embodiments, a variety of furnishings (e.g., beds, chairs, tables, counter, couches, exercise equipment, etc.) are available for use only as needed. In various exemplary embodiments, furnishings are stored above the dwelling zone in the storage zone. In various exemplary embodiments, some fixtures are lowered down to the floor to make room for furniture to be lowered. For example, a tabletop may drop down to floor level using a mechanism built into the utility zone below the floor. In preferred embodiments, the actuators for lowering and raising fixtures to and from floor level are in their legs. In preferred embodiments, the actuators are column lifters. The number of column lifters used for a particular fixture will vary based on the size and weight of the fixture.

Now referring to FIG. 28, an exemplary embodiment of an attachment mechanism 470 is shown. In this example, a cabinet, closet, or other storage compartment is attached at or near the bottom to a wire 471 that is used to raise and lower the cabinet. Furthermore, the connection is accessible via the bottom of the cabinet to allow access to the connection after installation. This allows the cabinet to be disconnected from the wires and removed for cabinet and lifter repair or replacement. In a preferred embodiment, at least two wires 471 on two corners are attached to the cabinet. In various preferred embodiments, the wire 471 is attached to a pin 472 that is dropped down a channel along a corner of the cabinet. The pin 472 includes a threaded bolt section 473 at its bottom. The pin passes through a narrow point and a nut 474 is attached to the bolt securing it in place. The nut may also be used to adjust the position of the pin relative to the bottom of the cabinet to level the cabinet.

In an exemplary embodiment, the table and seating portion of the bench drop down to the floor to make room for a bed that is lowered into place. In some embodiments, he backrest of the bench is fixed and becomes a headboard for the bed. In other embodiments, the backrest is lowered with the bench and/or may fold down over the bench. In various exemplary embodiments, the fixtures are supported by column lifters installed in the utility zone.

In exemplary embodiments, a bed is adapted to be lowered into the space above the lowered bench and table. In preferred embodiments, the bed is articulating between sleeping and sitting positions (i.e., like a hospital bed). In various exemplary embodiments, the bed is sized and positioned to leave a pathway along one side of the room. In preferred embodiments, the dwelling is intended to be wheelchair accessible, and the pathway is sufficient for a wheelchair to pass.

In various exemplary embodiments, storage units are lowered into various parts of the dwelling. For example, closets may be provided in the bathroom or bedroom modules, pantries in the kitchen, shelves for sheets or towels in the bedroom or bathroom, and so forth. The storage unit may be adapted to serve as a closet, dresser, pantry, etc. In various exemplary embodiments, the storage container comprises a door that opens and closes vertically and is counterbalanced with a weight to help maintain the door in an open position and make it easier to open and close. In various exemplary embodiments, the wires used to raise and lower the storage unit also pass through the edges of the door and serve as guides for raising and lowering the door.

In various exemplary embodiments, furniture that is lowered from the storage zone are preferable lowered using a cable and winch system. For safety and aesthetic reasons, it is preferred not to have cables in the dwelling zone. Therefore, in preferred embodiments, the cables are located at the edge of the dwelling zone. The cables are affixed to just one side of the furniture piece, such as a bed frame, and guides (e.g., C-shaped channels) are provided along the walls and the furniture is raised and lowered in cantilever fashion.

UTILITIES

In various exemplary embodiments, the dwelling unit contains a heat pump to provide heated or cooled air to HVAC ducts located in the utility zone. In preferred embodiments, the heat pump is located at the end of the dwelling opposite the bathroom module with access to outside air (i.e., this end of the dwelling is typically an outside wall). Air is drawn from outside the dwelling, conditioned, and distributed to one or more vents in the dwelling floor. In preferred embodiments, there is at least one air inlet inside the dwelling through which the heat pump also draws air to facilitate air circulation. In various preferred embodiments, the HVAC system includes a humidifier and/or dehumidifier.

In various exemplary embodiments, the HVAC system is designed for continuous operation rather than the typical cycle of on/off used in most systems. The system comprises, among other things, a variable speed fan capable of operating at low speed to maintain a flow of heated or cooled air into the dwelling sufficient to maintain a desired temperature without overheating or overcooling.

CONCLUSION

All patents, published patent applications, and other publications referred to herein are incorporated herein by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. Nevertheless, it is understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.

Claims

1. A modular dwelling, comprising:

a dwelling unit, comprising: a rectangular base; four exterior walls extending from the base to the roof; at least one entrance through one of the exterior walls; a utility zone disposed above the base; a residential zone disposed above the utility zone; a storage zone above the dwelling zone; a mechanical zone above the storage zone; and lifting devices in the mechanical zone adapted to raise and lower furnishings between the storage zone and the dwelling zone.

2. The modular dwelling of claim 1, comprising at least two dwelling units attached side-to-side.

3. The modular dwelling of claim 1, comprising at least two dwelling units attached top-to-bottom.

4. The modular dwelling of claim 1, wherein the dwelling unit comprises at least two modules.

5. The modular dwelling of claim 4, wherein one of the at least two modules is a convertible module adapted for conversion to different configurations.

6. The modular dwelling of claim 5, wherein the convertible module is converted into different configurations by raising or lowering furnishings between the dwelling zone and the storage zone.

7. The modular dwelling of claim 6, wherein the convertible room is converted into a bedroom by lowering a bed into the convertible room.

8. The modular dwelling of claim 4, wherein each of the at least two modules have the same dimensions.

9. The modular dwelling of claim 7, wherein each of the at least two modules are about 8.25 feet wide by 16.5 feet long.

10. The modular dwelling of claim 1, wherein the lifting devices comprise a motor, a spool, and a line.

11. The modular dwelling of claim 1, wherein the at least one entrance is located in an end of the dwelling unit.

12. The modular dwelling of claim 1, wherein the at least one entrance is located in a side of the dwelling unit.

13. The modular dwelling of claim 2, further comprising at least one passage between the at least two dwelling units attached side-to-side.

14. The modular dwelling of claim 13, wherein the passage comprises a panel that is moved to open the passage.

15. The modular dwelling of claim 14, wherein the panel is raised into the storage zone.

16. The modular dwelling of claim 1, wherein the height of the utility zone is about 16 inches.

17. The modular dwelling of claim 1, wherein the height of the dwelling zone is about 95 inches.

18. The modular dwelling of claim 1, wherein the height of the storage zone is about 48 inches.

19. The modular dwelling of claim 1, wherein the height of the mechanical zone is about 9 inches.

20. The modular dwelling of claim 1, wherein the height of the dwelling is about 14 feet.