Core Smart Zone Structure and Method

The following includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art nor material to the presently described or claimed inventions, nor that any publication or document that is specifically or implicitly referenced is prior art.

The present invention relates generally to the field of building construction of existing art and more specifically relates to a prefabricated core smart zone structure for use in construction of a building.

Traditional construction methods for homes involve a sequential process that begins with site preparation and foundation laying. Once the foundation is in place, the construction of walls, floors, and roof follows. In the case of kitchens and bathrooms, specialized plumbing and electrical work are integrated into the structure during the construction phase. On-site construction typically relies on a combination of skilled labor, such as carpenters, electricians, and plumbers, who work together to bring the architectural plans to life.

The on-site construction process can be time-consuming, often taking several months to complete, depending on the size and complexity of the home. Challenges such as weather conditions, labor availability, and material delivery delays can impact the overall timeline and cost of the project. Additionally, on-site construction may generate a significant amount of waste, as materials are cut and shaped at the location, leading to potential environmental concerns. Accordingly, a suitable solution is desired.

In view of the foregoing disadvantages inherent in the known building construction art, the present disclosure provides a novel building structure able to be adapted to multiple construction methods. The general purpose of the present disclosure, which will be described subsequently in greater detail, is a core smart zone structure prefabricated off-site and subsequently transported to an on-site location for use in constructing a building structure. This core smart zone structure is a ‘smart zone’ of the building structure. This core smart zone structure is able to be adapted to multiple buildings methods, to construct a ‘volumetric zone’ of the building structure from panels, modules and traditional construction methods.

According to one or more embodiments of the present disclosure, a core smart zone structure is disclosed herein. The core smart zone structure, or ‘smart zone’, may include a frame having a base, at least four main structure sides, a kitchen, at least one bathroom separated from the kitchen and a plurality of utility installations including electrical installations and plumbing installations with a heating and cooling system.

The kitchen, in some embodiments, is located centrally within the core smart zone structure and defined by a pair of inner walls and a front and rear outer side wall of at least one of the four main structure sides. The bathroom may be partitioned from the kitchen via one of the pair of inner walls. Further, in some embodiments, the electrical installations may comprise (but is not limited to) lighting, power outlets, switches and pre-cabling. The plumbing installations may comprise (but are not limited to) separate cold and hot water lines supplying the kitchen and the at least one bathroom and at least one water discharge line.

Further, a smart home technology system may be provided in the core smart zone structure and configured for controlling at least one of the plurality of utility installations. As such, a user terminal may be attached to an inner wall of the core smart zone structure to enable a user to control the utility installation(s) via the smart home technology system.

The core smart zone structure may be adapted to function within a broad range of construction methods selected to build the ‘volumetric zone’ of surrounding habitable rooms, such as living rooms, bedrooms, garage, lounge, dining room, etc. Construction methods may include, but are not limited to, traditional stick construction, modular components and the use of panelized materials.

In some embodiments, a method of providing a core smart zone structure is disclosed herein. The core smart zone structure may include the steps of: fabricating the frame as above; installing plumbing installations to the frame; installing electrical installations to the frame; installing a plurality of floor panels atop the base; installing a plurality of wall panels to an outer and inner surface of each of the at least four structure sides and the pair of inner walls; connecting the plumbing installations to plumbing fixtures in the at least one bathroom and the kitchen; connecting the electrical installations to electrical fixtures in the at least one bathroom and the kitchen; installing a ceiling panel atop the at least four structure sides; installing a heating and cooling system and associated ductwork; performing quality testing and inspection; packaging the core smart zone structure; and transporting the core smart zone structure to an on-site location.

For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.

The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.

As discussed above, embodiments of the present disclosure relate to building construction and more particularly to a core smart zone structure and construction method. The present disclosure provides an innovative approach to home construction, delivering spacious, energy-efficient family homes. The core smart zone structure and its adaption to multiple construction methods and building forms provides faster construction, reduced on-site labor requirements, and minimized on-site waste, all contributing to a more cost-effective solution.

Referring now more specifically to the drawings by numerals of reference,show various views of one or more embodiments of the present disclosure. Particularly,illustrate a core smart zone structurefor a building structure;illustrates a methodof providing the core smart zone structure;illustrate an example of a building structureand building method; andillustrates a methodof constructing a ‘volumetric zone’ module for the building structure, which in this example is a residential single family building structure, as shown in.

Dealing first with, illustrating the core smart zone structure. As above, an object of the present disclosure is to significantly reduce the amount of time taken to construct a building. One solution to this is to remove, or reduce, on-site fabrication of the components of the building. As such, the core smart zone structureis pre-fabricated off-site. Particularly, the core smart zone structuremay be pre-fabricated in an off-site factory. In some embodiments, the off-site factory may utilize automated features, such as robots, to fabricate each element of the core smart zone structure.

The core smart zone structureacts as the core module of the building structure, providing all (or most) ‘wet’ areas of the building structure—such as the kitchen and one or more bathrooms. The core smart zone structureis used as a ‘plug and play’ module in the construction of building structures through fixed interfaces. This allows a builder to utilize the core smart zone structureto adapt to their own volumetric space construction (including rooms such as living room, bedrooms, garage, lounge, dining room, etc.) to connect to pre-loaded features such as HVAC, pipework and electrical wiring.

As shown inin particular, the core smart zone structuremay include a framehaving a baseand at least four main structure sides,,,attached to the baseextending upwardly therefrom and defining an interior. Further, as shown in, a plurality of wall panelsmay line, or surround, an outer and inner surface of each of the at least four structure sides,,,

The main structure sides,,,may include a plurality of vertical, horizontal and diagonal structural elements, such as studs, beams and struts, welded together to form a rigid frame. In some embodiments, the framemay be made from a cold rolled steel and spot welded robotically off-site. Further, in some examples, as shown here, the framemay include a rectangular cuboid-like configuration. It should be appreciated that the core smart zone structuremay be constructed in any shape, size or configuration; however, the shape and size of the core smart zone structureis designed to enable easy transportation of the core smart zone structurefrom the off-site location to the on-site location. Particularly, the entire core smart zone structuremay be transported on a single truck to the on-site location.

In some embodiments, the core smart zone structuremay include a core smart zone structure roof, a ceiling panelthere-below, and a plurality of floor panelsabove the baseof the core smart zone structure. In some embodiments, the plurality of floor panelsmay include decorative flooring such as wood, laminate, carpet, or the like. It is contemplated that the plurality of floor panelsis assembled such that it is able to easily integrate with flooring in other parts of the buildingonce built. Further, some of the four main structure sides,,,(and corresponding wall panels) may include pre-made openings for windowsand doorsto be assembled in the core smart zone structure. It should be appreciated that the number, size, and positioning of doorsand windowsis flexible and not limited to what is shown here.

illustrates a front sectional view of the core smart zone structure, according to one or more embodiments of the present disclosure. A front wallhas been removed to illustrate various rooms in the core smart zone structure.

As above, the core smart zone structuremay include all, or most, ‘wet’ areas of the building structure. Particularly, the core smart zone structuremay include a kitchenwithin the core smart zone structureand at least one bathroompartitioned from the kitchen. As shown here (referenced in), the kitchenmay be defined by a pair of inner walls,and a frontand rearstructure side of the core smart zone structure. In some embodiments, the pair of inner walls,may defined by the frameand each outer and inner surface of each of the pair of inner walls,may be lined by one of the plurality of wall panels, similar to the structure sides,,,

In the example embodiment shown in these figures, the core smart zone structuremay include a single kitchenand two bathrooms,. In this example embodiment, the bathrooms,may be located at either side of the kitchenand partitioned by the pair of inner walls,; with one bathroompartitioned from the kitchenvia one side walland the other bathroompartitioned from the kitchenvia the other side wall. Further, as shown here, the kitchenmay be disposed centrally within the core smart zone structure.

As shown in, the kitchenand the bathrooms,may be finished with all plumbing, electrical, heating/cooling, and exhaust systems. In some embodiments, the kitchenmay include (but is not limited to including) kitchen countertops, kitchen cabinets, a stove, a kitchen sink, a refrigerator-freezerand an oven. Further, a range hoodmay be installed over the stove. In addition, the kitchenis shown in these figures to include an islandwith chairsfor enabling individuals to sit at the island. It should be appreciated however that other common, or non-common, kitchen appliances and/or items not discussed or shown here may be provided. The kitchenmay also include a plurality of storage featuresfor storing items, such as plates and cups, for the kitchen.

It should also be appreciated that the kitchenprovided in the core smart zone structureis flexible in configuration and may be supplied with less finished inclusions. For example, the core smart zone structuremay be provided as a ‘shell’ with no furniture and/or finishings, or with less furniture than is discussed and shown in these figures.

The bathrooms,may include (but are not limited to including) bathroom countertops, a bathroom sinkatop a bathroom cabinet, at least one bathing fixtureand a bathroom toilet. In some examples, the at least one bathing fixturemay be a bath, a shower, or a combination of the two. Each bathroom,may include similar fixtures or different fixtures. For example,illustrates bathroomhaving a showerand bathroomhaving a bath

As above, it should be appreciated that the bathrooms,provided in the core smart zone structureare flexible in configuration and may also include other common, or non-common, bathroom appliances, finishes, fixtures and/or items not discussed or shown here. It should also be appreciated that the core smart zone structureis not limited to including two bathrooms.

Referring now also to, which show various views of the core smart zone structurewith various elements removed to demonstrate other elements of the core smart zone structure.

As shown here, the core smart zone structure, including the kitchenand the at least one bathroom, may include various fully functioning utility installations for providing utility features to the core smart zone structureand to the building structureonce constructed. For example, as shown throughout, the core smart zone structuremay include pre-installed electrical installations; pre-installed plumbing installations; and pre-installed heating and cooling systems.

Dealing first withillustrating a top perspective sectional view of the core smart zone structure() and a side perspective sectional view of the core smart zone structure(). Here, the ceilingand the roofof the core smart zone structurehave been removed to demonstrate the various utility installations. As shown here, the pre-installed electrical installationsmay include lighting fixtures, power outlets; switches; electric wiring, and the like. The electric wiringmay include pre-cabling, allowing connection of other electrical installationsin areas of the building structureexternal to the core smart zone structure, which may be added during construction of the building structureor after construction is complete.

Also shown here inis the pre-installed heating and cooling system. As shown inin particular, one of the sidesof the core smart zone structurehas been removed to demonstrate the heating and cooling system. As also shown here, the heating and cooling systemincludes associated ductsfor conveying heated and cooled air around the building structure.

The plumbing installationsmay supply both hot and cold water to the core smart zone structureand the building structurewhen installed therein. As such, as shown in, the core smart zone structuremay include separate hot and cold water lines (and, respectively) supplying at least the kitchenand the bathroom,at, for example, the kitchen sink, the bathroom sink, the bathing fixture(s), the bathroom toiletand in some embodiments, the refrigerator-freezer. In some embodiments, the water lines,may fluidly connect to other areas and/or appliances of the building structure; for example, a utility room sink, a washing machine, and the like.

Dealing now also with, which demonstrates a top plan sectional view of the core smart zone structure. Each element has been removed (including the plurality of floor panels) to illustrate a top of the baseof the core smart zone structure, and more specifically, to illustrate discharge lines of the plumbing installationsinstalled within the core smart zone structure.

The core smart zone structuremay include at least one water discharge line. For example, in some embodiments, as shown here, the core smart zone structuremay include at least one of a blackwater discharge lineand/or a separate greywater discharge line. The blackwater discharge linemay fluidly couple to the bathroom toilet(s)so as to receive waste therefrom; and the greywater discharge linemay fluidly couple to other sources of water waste such as the kitchen sink, the bathroom sink(s), the bathing fixture(s), and the like. The greywater discharge linemay feed into a greywater tank or other reservoir (not illustrated) separate from blackwater waste, to enable recycling of the greywater.

Referring also to, there is shown a front view of a smart home technology system, according to one or more embodiments of the present disclosure. As shown here, the smart home technology systemmay include a user terminalattached to a wall panelwithin the core smart zone structure. The smart home technology systemmay be in communication with one or more of the utility installations, allowing a user to control the utility installations via the user terminal. For example, the user may easily control temperature in the building structurevia the user terminal. As shown here, the user may further control lighting, media, cameras, locks, or the like.also illustrates a switchattached to the inner wall.

Referring now towhich shows a flow diagram illustrating a methodof providing a core smart zone structure. As discussed above, the core smart zone structureis used as a ‘plug and play’ module in the construction of building structures, whether single family homes, multi-family homes, town houses, condominiums, etc.

As shown here, the methodmay, in some embodiments, comprise the steps of: step one, fabricating a frame as discussed above; step two, installing plumbing installations to the frame; step three, installing electrical installations to the frame; step four, installing a plurality of floor panels atop the base; step five, installing a plurality of wall panels to an outer and inner surface of each of the at least four structure sides and the pair of inner walls; step six, connecting the plumbing installations to plumbing fixtures in the at least one bathroom and the kitchen; step seven, connecting the electrical installations to electrical fixtures in the at least one bathroom and the kitchen; step eight, installing a ceiling panel atop the at least four structure sides; step nine, installing a heating and cooling system and associated ductwork; step ten, performing quality testing and inspection; step eleven, packaging the core smart zone structure; and step twelve, transporting the core smart zone structure to an on-site location.

In some embodiments, the entire core smart zone structure is transported to the on-site location on a single truck. Quality testing and inspection steps may evaluate and assess each element of the core smart zone structure. For example, utility installations may be checked, doors may be checked, windows may be checked, locks may be checked, the smart home system may be checked, etc. Further, the connection of plumbing and electrical may include connecting hot and cold lines to bathroom and kitchen sinks, connecting wiring to bathroom and kitchen lighting fixtures, etc., as has been discussed above. In some embodiments, the methodmay further comprise steps of furnishing the kitchen and bathroom(s); however, as above, the core smart zone structure may be provided as a ‘shell’ comprising no furniture, in some embodiments.

Referring now to, which demonstrate the construction of an example building structureand in particular, visually demonstrate a methodof constructing a building structure, a flowchart of which is shown inand will be discussed in more detail below. It should be appreciated that the building structureis not limited to the shape, size, or configuration shown here and various construction methods used with the present invention can produce a building structureof any desired shape, size, or configuration. It should also be appreciated that the core smart zone structurecan be readily adapted to a multitude of construction types and methodologies and the building structureshown and described inis given as one illustrative example not meant to limit use of the core smart zone structurein any way.

As shown here in these figures, the building structuremay include a foundation, the core smart zone structureand a plurality of pre-fabricated insulated structure panels,or other building construction materials. The foundationmay be configured for installation at a predetermined position at the on-site location (i.e., the desired final location of the building structure). In some embodiments, as shown here, the foundationmay be made up of a plurality of foundation panels. The plurality of foundation panels may be pre-fabricated off-site and transported to the on-site location for installation.

In some embodiments, as shown here, the plurality of foundation panels may include designated locations for attaching the core smart zone structureand the plurality of insulated structure panels,thereto. In particular, as shown in, the foundationmay include a designated areafor receiving the core smart zone structure, after being transported to the on-site location subsequent fabrication thereof. As shown here, the designated areamay be located centrally to the building structure, making the core smart zone structurethe core module of the building structurewhen installed thereon.demonstrates the core smart zone structurehaving been placed on the designated areaof the foundation.

As shown in, in some embodiments, the plurality of pre-fabricated insulated structure panels,may include a plurality of pre-fabricated insulated wall panelsand a plurality of pre-fabricated insulated roof panels. The insulated structure panels,may preferably be precision cut off-site, enabling efficient and accurate on-site installation. The insulative properties of the pre-fabricated insulated structure panels,may further contribute to high energy efficiency of the building structure.

As shown in, the plurality of pre-fabricated insulated wall panelsmay be configured for installation at predetermined locations on the foundationafter being transported to the on-site location subsequent fabrication thereof. The plurality of pre-fabricated insulated wall panelsmay form rooms within the building structure. For example, remaining rooms of the building structurecreated via the plurality of pre-fabricated insulated wall panelsmay be non ‘wet’ rooms, such as bedrooms, a living room, a dining room, a family room, a game room, a garage, and the like. Further, the plurality of pre-fabricated insulated wall panelsmay include, or may be arranged so as to provide, openings for windows and doors of the building.

In some embodiments, the plurality of pre-fabricated insulated wall panelsmay be arranged at predetermined locations on the foundationso as to form three separate partitioned living units. For example, one building structuremay be split into a main home unit, a studio unit and an apartment unit. These units may each include separate entry/exit points.

As shown in, the plurality of pre-fabricated insulated roof panelsmay be configured for installation atop the plurality of pre-fabricated insulated wall panelsafter having been transported to the on-site location subsequent fabrication thereof. The plurality of pre-fabricated insulated roof panelsmay form a roof for the building structure.

In some examples, as shown here, the roof may be angled. Accordingly, a plurality of angled insulated panelsmay be provided between the plurality of pre-fabricated insulated wall panelsand the plurality of pre-fabricated insulated roof panelsto support the plurality of pre-fabricated insulated roof panels. Further, trussesmay be erected in areas external to the plurality of pre-fabricated insulated wall panelsto support the roof panels.

Referring now towhich shows a flow diagram illustrating a method of constructing a building structure, according to an embodiment of the present disclosure. In particular, the methodmay include one or more components or features of the building structureand the core smart zone structureas described above. As discussed above, this methodis provided as an example only and is not meant to limit use of the core smart zone structurein any way. The core smart zone structureis contemplated for use with various construction methods and building types.

As illustrated, the methodmay include the steps of: step one, prefabricating the core smart zone structure; step two, prefabricating a plurality of insulated structure panels, as one of several construction methods which can adaptably use the core smart zone structure; step three, installing a foundation at a predetermined position at an on-site location, the foundation including a designated area for receiving the core smart zone structure; step four, transporting the core smart zone structure to the on-site location, which as above, may be via a single truck; step five, installing the core smart zone structure onto the designated area on the foundation; step six, transporting the plurality of insulated structure panels, or other preferred materials for chosen construction methodology, to the on-site location; step seven, installing the plurality of insulated wall panels, or other preferred materials for chosen construction methodology, at predetermined locations on the foundation, forming the volumetric zone with rooms for the building structure; and step eight, installing the plurality of insulated roof panels atop the plurality of wall panels, forming a roof for the building structure.

In some embodiments, step twomay involve precision cutting each insulated structure panels in an off-site controlled factory environment. Further, as discussed above, in some embodiments, the building structuremay include three separate partitioned living units. As such, in some embodiments, step sevenmay involve installing the insulated wall panels such that three separate partitioned living units are formed.

It should be noted that the steps described in the methodand methodcan be carried out in many different orders according to user preference or not carried out at all in some instances. In addition, the steps can be adapted to flexibly accommodate the core structure to be used in multiple existing construction methodologies with a variety of materials. The use of “step of” should not be interpreted as “step for”, in the claims herein and is not intended to invoke the provisions of 35 U.S.C. § 112(f). It should also be noted that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods are taught herein.

It should be appreciated that common but well understood elements that are useful or necessary in a commercially feasible embodiment are often not discussed or shown throughout in order to facilitate a clearer view of the various embodiments of the present invention. For example, weatherproofing elements, door and window installation elements, and the like, are not discussed herein but should be appreciated as incorporated in a commercially feasible embodiment.