PORTABLE HOME

Abstract

A portable home assembly can include a wall panel including mass plywood, a floor panel including mass plywood, and a roof including metal. The wall panel, the floor panel, and the roof can be configured to be manufactured as separate pieces, shipped in a single standard shipping container, and assembled together to form a complete home. A method of shipping a portable home assembly can include providing a portable home assembly having separable components, positioning all of the separable components into a single standard shipping container, and transporting the separate components in the single standard shipping container to a place of assembly.

Description

FIELD

The described embodiments relate generally to architectural buildings. More particularly, the present embodiments relate to portable and sustainable homes.

BACKGROUND

Recent increases in cost of living expenses in urban areas are due in part to rising housing costs. Real estate values are increasing, and in response, more housing units are being built. However, construction is slow and expensive. Transportation of building materials is difficult and time consuming, particularly stick framed housing. In addition, the number of experienced laborers able to perform quality construction is decreasing. Energy costs are also rising, shifting public focus toward environmental issues. In light of this, consumers want sustainable housing solutions. Fast, economical, efficient, and compact housing is desired to meet consumer needs.

SUMMARY

In at least one example of the present disclosure, a home assembly includes a wall panel including mass plywood, a floor panel including mass plywood, and a roof. In one example, the home assembly is configured to be manufactured in separate pieces, the entire home assembly is shipped in two or less single standard shipping containers, and the home assembly is configured to be assembled together to form a complete home.

In some examples, the home assembly further includes a plurality of wall panels, a plurality of doors, a window, a roof, cabinets, electrical components, plumbing components, HVAC components, insulation, railing, finish work, countertops, bathroom fixtures, and kitchen fixtures. In some examples, the roof is a metal roof.

In some examples, the home assembly can include an electrical access through-hole defined by one of the plurality of wall panels, and a plumbing through-hole defined by one of the plurality of wall panels. The home assembly can further include the electrical components and the plumbing components assembled on an exterior surface of the wall panels. Additionally, the insulation can be attached to the exterior surface of the wall panels. In some examples, the home assembly further includes drywall attached over the insulation.

In some additional examples, the entire home assembly is shipped in a single standard shipping container. In some examples, the wall panel is 4 inches thick. The home assembly can further include fasteners for joining the home assembly to form a complete home. The assembly can be free of a foundation.

In one embodiment, a packaged complete home assembly includes a plurality of wall panels including mass plywood, a plurality of floor panels including mass plywood, a metal roof, a plurality of doors, windows, cabinets, electrical components, plumbing components, HVAC components, insulation, finish work, countertops, bathroom fixtures, and kitchen fixtures. In some examples, the home assembly is configured to be manufactured in separate pieces. In some examples, the entire home assembly is nested and packaged in two or less single standard shipping containers, and the home assembly is configured to be assembled together to form a complete home.

In some examples, the packaged complete home assembly further includes an electrical access through-hole defined by one of the plurality of wall panels, and a plumbing through-hole defined by one of the plurality of wall panels. In some examples, the electrical components and the plumbing components are assembled on an exterior surface of the wall panels. Additionally, the packaged complete home assembly can further include insulation attached to the exterior surface of the wall panels. In yet other examples, the packaged complete home assembly can further include drywall attached over the insulation.

In some examples of the packaged complete home assembly, the entire home assembly is shipped in a single standard shipping container. In some examples, each of the plurality of wall panels is 4 inches thick. The packaged complete home assembly can include fasteners for joining the home assembly to form a complete home.

In some examples, a method of shipping a complete home assembly can include providing a complete home assembly having separate components, positioning all of the separate components in no more than two standard shipping containers, and transporting the separate components in the no more than two standard shipping containers to a place of assembly.

In some examples, no more than two standard shipping containers includes a single standard shipping container, and further including assembling the complete home assembly on a foundation.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:

FIG. 1 shows a perspective view of an example of a portable home assembly;

FIG. 2 shows a side view of an example of a shipping container used to transport a portable home assembly;

FIG. 3 shows an exploded view of an example of a portable home assembly;

FIG. 4 shows a portion of an example of a portable home assembly;

FIG. 5 shows an example of a wall panel;

FIG. 6 shows a side view of a ceiling panel secured to a wall panel; and

FIG. 7 shows a flowchart illustrating a method of manufacturing a mass plywood panel.

DETAILED DESCRIPTION

The present description provides examples, and is not limiting of the scope, applicability, or configuration set forth in the claims. Thus, it will be understood that changes can be made in the function and arrangement of elements discussed without departing from the spirit and scope of the disclosure, and various embodiments can omit, substitute, or add other procedures or components as appropriate. For instance, methods described can be performed in an order different from that described, and various steps can be added, omitted, or combined. Also, features described with respect to some embodiments can be combined in other embodiments.

Reference will now be made in detail to representative examples illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred example or embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims.

The following disclosure generally relates to architectural buildings. More particularly, the present disclosure relates to portable home assemblies. The portable home assemblies described herein can include separate components, including wall panels, roof components, and interior features, which can be separately manufactured using energy efficient materials and processes and positioned all together within a single, standard shipping container for transport to an assembly site. At the assembly site, the separate components of the portable home assemblies can be assembled and secured together to form a complete home. A residential home is one example of a building that can be manufactured and shipped as described herein, but is not meant as limiting. As used herein, the phrase “complete home” shall be understood as meaning a habitable home complying with municipal construction and habitation regulations. Other architectural structures and building can likewise be portably manufactured, shipped, and assembled, including office spaces, restrooms, and other shelters or buildings.

The separate components of the portable home assemblies described herein can be manufactured using sustainable processes and materials such that the portable home assemblies are energy efficient and economical. In addition, the shipment of the portable home assemblies described herein can result in economical, efficient, and compact housing to meet consumer needs.

Specific examples and embodiments of portable or pre-manufactured homes and buildings, are discussed below with reference to FIGS. 1-7. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. Furthermore, as used herein, a system, a method, an article, a component, a feature, or a sub-feature comprising at least one of a first option, a second option, or a third option should be understood as referring to a system, a method, an article, a component, a feature, or a sub-feature that can include one of each listed option (e.g., only one of the first option, only one of the second option, or only one of the third option), multiple of a single listed option (e.g., two or more of the first option), two options simultaneously (e.g., one of the first option and one of the second option), or combination thereof (e.g., two of the first option and one of the second option).

FIG. 1 shows an example of a home 100. The home 100 can be a net zero energy home, producing energy equal to or greater than the amount of energy the home 100 consumes. In addition, the home 100 can be a renewable home including renewable mass ply panels, recycled content, and reclaimed metals. In some examples, the home 100 can include multiple floors, including a ground floor and a second floor above the ground floor, to create a comfortable living space while maintaining a small physical footprint. The small footprint of the home 100 allows for more homes to be built per unit area, increasing profits for developers and decreasing cost for consumers.

The illustrated example of the home 100 shown in FIG. 1 is exemplary only and not meant to be limiting. Other examples of similar homes, according to the present disclosure, can include various sizes, footprints, floors/levels, and architectural layouts and features. In some examples, the home 100 can include only a single, ground level. In other examples, the home 100 can include three or more levels. In some embodiments, the home 100 can include rooms with plumbing, such as a kitchen or bathroom. The home 100 can include electrical components such as outlets, breaker boxes, and electrical wiring. The home can be configured to receive a variety of voltages, such as 110 Volt power or 220 Volt power, from various sources. According to one example, the main power input to the house is pre-determined and formed in the panels prior to assembly. In some examples, the main access to plumbing and electrical is provided through the panels, but the electrical and plumbing feed lines can be run on the exterior or interior of the panels, rather than through the center of the panels, thereby adding to the integrity and insulative properties of the panels. Additionally, in some examples, the insulation can be formed on the exterior of the structural panels. In other examples, the outlet, switch, and fixture holes are pre formed in the panels, as are the conduits for pulling electrical wire to distribute the power. According to this embodiment, the pre-formed holes further add to construction efficiency and cost certainty and savings. Power sources for the home 100 can include, but are not limited to a municipal power grid, solar panels, wind turbines, electrical generators, or other sources of electricity. The components of the home 100, including the panels noted above, can be removably secured together and taken apart such that the entire home 100 can be arranged in a compact configuration for shipping. The separable components of the home 100 can be positioned in a single, standard shipping container for transportation to an assembly site. In some examples, the separable components of the home 100 can be positioned in two standard shipping container for transportation to an assembly site. As used herein, the phrase standard shipping container shall be interpreted to refer to an ISO compliant shipping container. According to one exemplary embodiment, the ISO general shipping container is approximately 8.5 ft. high and 8 ft. wide. The length of the standard shipping container can vary from 20 ft., to 40 ft., or more. Additional shipping container sizes may be used to store and ship entire home packages, as detailed below.

FIG. 2 shows an example of a standard shipping container 201 into which all components of a complete home can fit. According to one example, all components of a complete home include, but is not limited to, panels, doors, windows, roof, cabinets, electrical components, plumbing components, flooring components, dry-wall, HVAC components, insulation, railing, finish work, countertops, bathroom and kitchen fixtures, and the like. The container 201 can be transported using a plurality of methods including by ground transport as shown. Other forms of transportation can include shipping by plane, ocean liner, or helicopter. The use of only one (or two) shipping container(s) 201 for carrying and shipping the home 100 shown in FIG. 1 can decrease shipping expenses and simplify the shipping process. For example, shipping the home 100 in a single—or two—shipping container(s) 201 can decrease shipping time compared to shipping a home using multiple containers or in delivering components separately. Shipping the home 100 in a single container 201 also removes the need for wide loads often used for transporting pre-fabricated homes, which are slower than standard shipping containers and carry more risk. Moreover, shipping the entire home 100 in the single shipping container 201 ensures that the entire home is present upon arrival, eliminating the need to wait for the delivery of additional building supplies, which often results in delay and frustration.

Increasing the mobility of the home 100 via the single shipping container 201 increases the potential locations at which the home 100 can be fabricated and manufactured. For example, because the home 100 can be shipped easily and conveniently, the distance between the place of manufacture and the place of assembly does not increase the cost of shipping compared with the more expensive shipment of pre-fabricated homes. In this way, the home 100 can be built in a wider variety of locations than other pre-fabricated homes. The compact size of the shipping container can also allow transportation vehicles reach more remote, steep, or terrain otherwise inaccessible to traditional shipping methods.

FIG. 3 shows an exploded view of an example of a home 300, including separable components that can be disassembled to fit in the single shipping container 201 shown in FIG. 2 and assembled to form the home 100 shown in FIG. 1. In some examples, all materials and components can be removed and the home 100 can be assembled at the delivery site when the shipping container 201 arrives. According to one example, the materials and components can be removed from the container(s) and assembled on a pre-formed foundation using provided fasteners. The use of pre-fabricated building materials removes the need for workers skilled in construction methods such as framing, dry wall, plastering, finish work, and so forth. There is also no waste from cutting materials on-site as seen in stick-built construction. Faster construction is also facilitated by receiving all components at once. This reduction in waste results in cleaner, more efficient construction. The lack of on-site fabrication also decreases the need for larger machinery, which can also decrease noise pollution in populated areas or wildlife habitats.

In at least one example, as shown in FIG. 3, the home 300 can include a roof 302. The roof 302 can be formed of one or more metal materials. The metal materials can be durable and lightweight. In one example, the metal material and construction of the roof 302 can be configured to last at least 50 years before needing to be replaced. In other examples, the lifespan of the roof can be configured to be longer or shorter than 50 years. In other examples, the roof 302 can be built of other appropriate materials such as mass plywood materials covered by a metal roof or a typical shingle style. In yet other examples, the roof 302 can be built out of other materials not specified herein. The home 300 can also include various outer walls 304, including opposing sidewalls and a rear wall and/or from wall or frame 306. The walls 304 can be formed using mass plywood materials, including pre-fabricated panels formed from renewable wood fiber. In some examples, the front frame 306 can include window frames 308 to accommodate energy efficient windows to transmit light into the home 300.

The home 300 can also include various inner walls 310 separating spaces within the home 300 and defining separate rooms therein, including the kitchen 301 and the bathroom 303. In at least one example, the various inner walls 310 can be formed using mass plywood materials, including pre-fabricated panels formed from renewable wood fiber. In some examples, some of the inner walls 310 can be load-bearing walls, and in some examples, some of the inner walls 310 are not load-bearing walls. In at least one example, the home 300 can include a separate floor panel 312 formed using mass plywood materials, including pre-fabricated panels of renewable wood fiber as well.

In addition to the various panels and walls forming the home 300 shown in FIG. 3, some examples of homes described herein can also include internal space-saving and energy-saving features, including compact and efficient storage systems 316 and low energy heating and cooling systems 314. The heating and cooling systems of the home 300 can include ductless systems, as shown, which do not require time consuming and expensive duct installation and duct space within the walls of the home 300. To accomplish this, the pre-fabricated components contained in the shipping container 201 can include channels. These channels can be used as air ducts to direct heating or cooling into one or more rooms within the home 300.

FIG. 4 shows a partially assembled section of a second floor 400 of a home, which can be incorporated into the various examples of homes described herein. As shown in FIG. 4, the second floor 400 can include a bathroom 401, similar to the bathroom 303 shown in FIG. 3 positioned directly above the kitchen 301. The vertically stacked position of the bathroom 401 (303 in FIG. 3) relative to the kitchen 301 can enable centralized utilities to be routed central to the home 300. In at least one example, all mechanical, plumbing, and electrical (MEP) components can be attached to the exterior of mass ply panels (MPP). Shorter distances between utilities and a lack of internal channels in MPP can result in efficient use of materials and faster construction. For example, the stacked position of the bathroom 401 relative to the kitchen 303 reduces the distance between the bathroom 401 and the kitchen 303. This can facilitate more efficient use MEP components and other components such as those needed for plumbing. MEP and piping can be expensive, and decreasing the amount used can both decrease the cost of the materials as well as lessen the impact of manufacturing on the environment.

FIG. 5 shows a wall assembly 500 containing mass ply panel (MPP). In at least one example, the MPP of the wall assembly 500 can be about 4-inches thick. MPP can be utilized for both its structural rigidity and insulation properties. In some examples, the thickness can be varied to fit a myriad of strength or insulation requirements. In at least one example, the MPP of the wall assembly 500 can have a shear strength of approximately 2925 lbf/ft in the major strength direction and an R-value of about 21. As used herein, the R-value refers to the capacity of a material to resist the flow of heat. MPP is a solid laminate made from renewable materials, differing from conventional structural insulated panels made of insulation between two panels. The use of a solid laminate decreases production time and simplifies the manufacturing process. Larger and more complex shapes such as walls with windows can be manufactured more efficiently since assembly of the insulated panel is not required on-site. This allows an entire wall panel, such as the wall panels 304 and internal walls 310 shown in FIG. 3, to be manufactured as one piece, thus decreasing waste during production. Single piece wall panels also remove the need for many panels to be fastened together on-site to create the wall, further making construction more efficient. Increased efficiency in manufacturing and construction can consequently result in economic benefits for both the developer and consumer, as well as. Increased efficiency in manufacturing and construction can also provide environmental benefits through the decrease in materials used, energy required to produce such materials, and chemical processes used to treat building materials.

FIG. 6 shows the fastening method of two MPPs, including a wall panel 616 and a kitchen ceiling panel 618. In at least one example, the wall panel 616 can be mounted to the ceiling panel 618 using a ⅝″ diameter threaded rod 601 with 3×3 PL washer bearing and a custom L bracket. In some examples, a threaded rod fastener can add shear strength to the joint and can therefore be used in place of less desirable fasteners such as nails. In other examples, a combination of screws and nails with a total capacity of about 3,333 lb. can be used to fasten the MPP wall sections to each other. Angle brackets using M20 anchors and LBA nails can be used to fasten wall panels to floor panels on the first level. Additional components, including drywall components 620 and tile components 622 can also be secured to the wall panel 616 and/or the ceiling panel 618.

FIG. 7 illustrates a flowchart showing an example of a method 700 of manufacturing the MPPs described herein. The MPP can be received at step 724 of the method 700. At step 726 of the method 700, the MPP can be fixed in place and cut to size. In at least one example, a jig can be used to make cutouts of desired shapes. The use of a jig can allow workers not skilled in construction methods to easily produce panels that conform to design tolerances. The use of a jig can also allow workers not skilled in construction methods to produce large numbers of panels efficiently. These cutouts can be for windows, doors, or other features. At step 728 of the method 700, the MPP can be packaged and loaded into a standard shipping container, such as the shipping container 201 shown in FIG. 2.

Each of the embodiments described in the detailed description above may include any of the features, options, and possibilities set out in the present disclosure, including those under the other independent embodiments, and may also include any combination of any of the features, options, and possibilities set out in the present disclosure and figures.

The articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one example” or “an example” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.

A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Claims

1. A home assembly, comprising: a wall panel comprising mass plywood;a floor panel comprising mass plywood; anda roof;wherein:the home assembly is configured to be manufactured in separate pieces;the entire home assembly is shipped in two or less single standard shipping containers; andthe home assembly is configured to be assembled together to form a complete home.

2. The home assembly of claim 1, wherein the home assembly further comprises a plurality of wall panels, a plurality of doors, a window, a roof, cabinets, electrical components, plumbing components, HVAC components, insulation, railing, finish work, countertops, bathroom fixtures, and kitchen fixtures.

3. The home assembly of claim 1, wherein the roof comprises metal.

4. The home assembly of claim 2, further comprising: an electrical access through-hole defined by one of the plurality of wall panels; anda plumbing through-hole defined by one of the plurality of wall panels.

5. The home assembly of claim 4, wherein the electrical components and the plumbing components are assembled on an exterior surface of the wall panels.

6. The home assembly of claim 5, wherein the insulation is attached to the exterior surface of the wall panels.

7. The home assembly of claim 6, further comprising drywall attached over the insulation.

8. The home assembly of claim 2, wherein the entire home assembly is shipped in a single standard shipping container.

9. The home assembly of claim 1, wherein the wall panel is 4 inches thick.

10. The home assembly of claim 2, further comprising fasteners for joining the home assembly to form a complete home.

11. The home assembly of claim 10, wherein the assembly is free of a foundation.

12. A packaged complete home assembly, comprising: a plurality of wall panels comprising mass plywood;a plurality of floor panels comprising mass plywood;a metal roof;a plurality of doors, windows, cabinets, electrical components, plumbing components, HVAC components, insulation, finish work, countertops, bathroom fixtures, and kitchen fixtureswherein:the home assembly is configured to be manufactured in separate pieces;the entire home assembly is nested and packaged in two or less single standard shipping containers; andthe home assembly is configured to be assembled together to form a complete home.

13. The packaged complete home assembly of claim 12, further comprising: an electrical access through-hole defined by one of the plurality of wall panels; anda plumbing through-hole defined by one of the plurality of wall panels;wherein the electrical components and the plumbing components are assembled on an exterior surface of the wall panels.

14. The packaged complete home assembly of claim 13, further comprising insulation attached to the exterior surface of the wall panels.

15. The packaged complete home assembly of claim 14, further comprising drywall attached over the insulation.

16. The packaged complete home assembly of claim 12, wherein the entire home assembly is shipped in a single standard shipping container.

17. The packaged complete home assembly of claim 12, wherein each of the plurality of wall panels is 4 inches thick.

18. The packaged complete home assembly of claim 12, further comprising fasteners for joining the home assembly to form a complete home.

19. A method of shipping a complete home assembly, comprising: providing a complete home assembly having separate components;positioning all of the separate components in no more than two standard shipping containers; andtransporting the separate components in the no more than two standard shipping containers to a place of assembly.

20. The method of claim 19, wherein the no more than two standard shipping containers comprises a single standard shipping container; and further comprising assembling the complete home assembly on a foundation.