Patent application title:

CORE SMART ZONE STRUCTURE AND METHOD

Publication number:

US20250314058A1

Publication date:
Application number:

18/630,227

Filed date:

2024-04-09

Smart Summary: A new building design allows for parts to be made in a factory and then brought to the construction site. This design includes important areas like kitchens and bathrooms, which are already built and ready to use. It also comes with necessary plumbing and electrical systems installed. By using this method, construction can be faster and more efficient. Overall, it simplifies the building process by preparing key sections ahead of time. 🚀 TL;DR

Abstract:

A core smart zone structure and method are disclosed herein. The core smart zone structure is fabricated off-site and transported to an on-site location for assembly and construction of a building structure. The prefabricated core smart zone structure includes the ‘wet’ rooms of the building, such as a kitchen and one or more bathrooms, and preinstalled utility installations for serving the prefabricated core smart zone structure and other rooms of a building structure.

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Classification:

E04B1/34869 »  CPC main

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs; Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form Elements for special technical purposes, e.g. with a sanitary equipment

E04B1/3483 »  CPC further

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs; Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form; Elements not integrated in a skeleton the supporting structure consisting of metal

E04B1/34861 »  CPC further

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs; Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form; Elements not integrated in a skeleton particular arrangement of habitable rooms or their component parts; modular co-ordination

E04B1/348 IPC

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form

Description

BACKGROUND OF THE INVENTION

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.

SUMMARY OF THE INVENTION

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.

BRIEF DESCRIPTION OF FIGURES

The figures which accompany the written portion of this specification illustrate embodiments and methods of use for the present disclosure, core smart zone structure and method, constructed and operative according to the teachings of the present disclosure.

FIG. 1 is a front perspective view of a core smart zone structure including a base and four structure sides, according to one or more embodiments of the disclosure.

FIG. 2 is a top perspective view of a core smart zone structure including a frame including the base and the four structure sides, according to one or more embodiments of the disclosure.

FIG. 3 is a front sectional view of the core smart zone structure including two bathrooms and a kitchen, according to one or more embodiments of the disclosure.

FIG. 4 is a top perspective sectional view of the core smart zone structure illustrating utility installations, according to one or more embodiments of the disclosure.

FIG. 5 is a side perspective sectional view of the core smart zone structure illustrating the utility installations, according to one or more embodiments of the disclosure.

FIG. 6 is a top plan sectional view of the core smart zone structure illustrating a blackwater discharge line and a grey water discharge line integrated into the base of the core smart zone structure, according to one or more embodiments of the disclosure.

FIG. 7 is a front view of an example user terminal used as part of a smart home technology system pre-installed in the core smart zone structure, according to one or more embodiments of the disclosure.

FIG. 8 is a flow diagram illustrating an example method of providing a core smart zone structure, according to an embodiment of the present disclosure.

FIG. 9A is a top perspective view of a foundation of an example residential building structure, the foundation having a designated area for accepting the core smart zone structure, according to one or more embodiments of the disclosure.

FIG. 9B is a top perspective view of the core smart zone structure placed on the designated area of the foundation of the example residential building structure, according to one or more embodiments of the disclosure.

FIG. 10 is a top perspective view of a plurality of insulated wall panels installed on the foundation to form rooms for the example residential building structure, according to one or more embodiments of the disclosure.

FIG. 11 is a top perspective view of a plurality of insulated roof panels installed atop the insulated wall panels to form a roof for the example residential building structure, illustrating one adaptable use of the core smart zone structure, according to one or more embodiments of the disclosure.

FIG. 12 is a flow diagram illustrating an example method of constructing a building structure, according to an embodiment of the present disclosure.

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

DETAILED DESCRIPTION

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, FIGS. 1-12 show various views of one or more embodiments of the present disclosure. Particularly, FIGS. 1-7 illustrate a core smart zone structure 100 for a building structure 200; FIG. 8 illustrates a method 300 of providing the core smart zone structure 100; FIGS. 9A-11 illustrate an example of a building structure 200 and building method; and FIG. 12 illustrates a method 400 of constructing a ‘volumetric zone’ module for the building structure 200, which in this example is a residential single family building structure 200, as shown in FIGS. 9A-11.

Dealing first with FIGS. 1-3, illustrating the core smart zone structure 100. As above, an object of the present disclosure is to significantly reduce the amount of time taken to construct a building 200. One solution to this is to remove, or reduce, on-site fabrication of the components of the building 200. As such, the core smart zone structure 100 is pre-fabricated off-site. Particularly, the core smart zone structure 100 may 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 100.

The core smart zone structure 100 acts as the core module of the building structure 200, providing all (or most) ‘wet’ areas of the building structure 200—such as the kitchen and one or more bathrooms. The core smart zone structure 100 is 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 structure 100 to 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 in FIG. 2 in particular, the core smart zone structure 100 may include a frame 141 having a base 101 and at least four main structure sides 102 a, 102 b, 102 c, 102 d attached to the base 101 extending upwardly therefrom and defining an interior 143. Further, as shown in FIG. 2, a plurality of wall panels 142 may line, or surround, an outer and inner surface of each of the at least four structure sides 102 a, 102 b, 102 c, 102 d.

The main structure sides 102 a, 102 b, 102 c, 102 d may include a plurality of vertical, horizontal and diagonal structural elements, such as studs, beams and struts, welded together to form a rigid frame 141. In some embodiments, the frame 141 may be made from a cold rolled steel and spot welded robotically off-site. Further, in some examples, as shown here, the frame 141 may include a rectangular cuboid-like configuration. It should be appreciated that the core smart zone structure 100 may be constructed in any shape, size or configuration; however, the shape and size of the core smart zone structure 100 is designed to enable easy transportation of the core smart zone structure 100 from the off-site location to the on-site location. Particularly, the entire core smart zone structure 100 may be transported on a single truck to the on-site location.

In some embodiments, the core smart zone structure 100 may include a core smart zone structure roof 111, a ceiling panel 112 there-below, and a plurality of floor panels 109 above the base 101 of the core smart zone structure 100. In some embodiments, the plurality of floor panels 109 may include decorative flooring such as wood, laminate, carpet, or the like. It is contemplated that the plurality of floor panels 109 is assembled such that it is able to easily integrate with flooring in other parts of the building 200 once built. Further, some of the four main structure sides 102 a, 102 b, 102 c, 102 d (and corresponding wall panels 142) may include pre-made openings for windows 114 and doors 113 to be assembled in the core smart zone structure 100. It should be appreciated that the number, size, and positioning of doors 113 and windows 114 is flexible and not limited to what is shown here.

FIG. 3 illustrates a front sectional view of the core smart zone structure 100, according to one or more embodiments of the present disclosure. A front wall 102 a has been removed to illustrate various rooms in the core smart zone structure 100.

As above, the core smart zone structure 100 may include all, or most, ‘wet’ areas of the building structure 200. Particularly, the core smart zone structure 100 may include a kitchen 103 within the core smart zone structure 100 and at least one bathroom 104 partitioned from the kitchen 103. As shown here (referenced in FIG. 1), the kitchen 103 may be defined by a pair of inner walls 115 a, 115 b and a front 102 a and rear 102 d structure side of the core smart zone structure 100. In some embodiments, the pair of inner walls 115 a, 115 b may defined by the frame 141 and each outer and inner surface of each of the pair of inner walls 115 a, 115 b may be lined by one of the plurality of wall panels 142, similar to the structure sides 102 a, 102 b, 102 c, 102 d.

In the example embodiment shown in these figures, the core smart zone structure 100 may include a single kitchen 103 and two bathrooms 104 a, 104 b. In this example embodiment, the bathrooms 104 a, 104 b may be located at either side of the kitchen 103 and partitioned by the pair of inner walls 115 a, 115 b; with one bathroom 104 partitioned from the kitchen 103 via one side wall 115 a and the other bathroom 104 b partitioned from the kitchen 103 via the other side wall 115 b. Further, as shown here, the kitchen 103 may be disposed centrally within the core smart zone structure 100.

As shown in FIGS. 1-2, the kitchen 103 and the bathrooms 104 a, 104 b may be finished with all plumbing, electrical, heating/cooling, and exhaust systems. In some embodiments, the kitchen 103 may include (but is not limited to including) kitchen countertops 11, kitchen cabinets 12, a stove 13, a kitchen sink 14, a refrigerator-freezer 15 and an oven 16. Further, a range hood 17 may be installed over the stove 13. In addition, the kitchen 103 is shown in these figures to include an island 18 with chairs 19 for enabling individuals to sit at the island 18. 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 kitchen 103 may also include a plurality of storage features 24 for storing items, such as plates and cups, for the kitchen 103.

It should also be appreciated that the kitchen 103 provided in the core smart zone structure 100 is flexible in configuration and may be supplied with less finished inclusions. For example, the core smart zone structure 100 may 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 104 a, 104 b may include (but are not limited to including) bathroom countertops 19, a bathroom sink 20 atop a bathroom cabinet 23, at least one bathing fixture 21 and a bathroom toilet 22. In some examples, the at least one bathing fixture 21 may be a bath 21 a, a shower 21 b, or a combination of the two. Each bathroom 104 a, 104 b may include similar fixtures or different fixtures. For example, FIG. 2 illustrates bathroom 104 b having a shower 21 b and bathroom 104 a having a bath 21 a.

As above, it should be appreciated that the bathrooms 104 a, 104 b provided in the core smart zone structure 100 are 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 structure 100 is not limited to including two bathrooms.

Referring now also to FIGS. 4-6, which show various views of the core smart zone structure 100 with various elements removed to demonstrate other elements of the core smart zone structure 100.

As shown here, the core smart zone structure 100, including the kitchen 103 and the at least one bathroom 104, may include various fully functioning utility installations for providing utility features to the core smart zone structure 100 and to the building structure 200 once constructed. For example, as shown throughout FIGS. 3-5, the core smart zone structure 100 may include pre-installed electrical installations 105; pre-installed plumbing installations 106; and pre-installed heating and cooling systems 107.

Dealing first with FIGS. 4-5 illustrating a top perspective sectional view of the core smart zone structure 100 (FIG. 4) and a side perspective sectional view of the core smart zone structure 100 (FIG. 5). Here, the ceiling 112 and the roof 111 of the core smart zone structure 100 have been removed to demonstrate the various utility installations. As shown here, the pre-installed electrical installations 105 may include lighting fixtures 123, power outlets 124; switches 125; electric wiring 126, and the like. The electric wiring 126 may include pre-cabling, allowing connection of other electrical installations 105 in areas of the building structure 200 external to the core smart zone structure 100, which may be added during construction of the building structure 200 or after construction is complete.

Also shown here in FIGS. 4-5 is the pre-installed heating and cooling system 107. As shown in FIG. 5 in particular, one of the sides 102 of the core smart zone structure 100 has been removed to demonstrate the heating and cooling system 107. As also shown here, the heating and cooling system 107 includes associated ducts 107 a for conveying heated and cooled air around the building structure 200.

The plumbing installations 106 may supply both hot and cold water to the core smart zone structure 100 and the building structure 200 when installed therein. As such, as shown in FIGS. 4-5, the core smart zone structure 100 may include separate hot and cold water lines (116 and 117, respectively) supplying at least the kitchen 103 and the bathroom 104 a, 104 b at, for example, the kitchen sink 14, the bathroom sink 20, the bathing fixture(s) 21, the bathroom toilet 22 and in some embodiments, the refrigerator-freezer 15. In some embodiments, the water lines 116, 117 may fluidly connect to other areas and/or appliances of the building structure 200; for example, a utility room sink, a washing machine, and the like.

Dealing now also with FIG. 6, which demonstrates a top plan sectional view of the core smart zone structure 100. Each element has been removed (including the plurality of floor panels 109) to illustrate a top of the base 101 of the core smart zone structure 100, and more specifically, to illustrate discharge lines of the plumbing installations 106 installed within the core smart zone structure 100.

The core smart zone structure 100 may include at least one water discharge line. For example, in some embodiments, as shown here, the core smart zone structure 100 may include at least one of a blackwater discharge line 119 and/or a separate greywater discharge line 118. The blackwater discharge line 119 may fluidly couple to the bathroom toilet(s) 22 so as to receive waste therefrom; and the greywater discharge line 118 may fluidly couple to other sources of water waste such as the kitchen sink 14, the bathroom sink(s) 20, the bathing fixture(s) 21, and the like. The greywater discharge line 118 may feed into a greywater tank or other reservoir (not illustrated) separate from blackwater waste, to enable recycling of the greywater.

Referring also to FIG. 7, there is shown a front view of a smart home technology system 130, according to one or more embodiments of the present disclosure. As shown here, the smart home technology system 130 may include a user terminal 131 attached to a wall panel 142 within the core smart zone structure 100. The smart home technology system 130 may be in communication with one or more of the utility installations, allowing a user to control the utility installations via the user terminal 131. For example, the user may easily control temperature in the building structure 200 via the user terminal 131. As shown here, the user may further control lighting, media, cameras, locks, or the like. FIG. 6 also illustrates a switch 125 attached to the inner wall 142.

Referring now to FIG. 8 which shows a flow diagram illustrating a method 300 of providing a core smart zone structure 100. As discussed above, the core smart zone structure 100 is 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 method 300 may, in some embodiments, comprise the steps of: step one 301, fabricating a frame as discussed above; step two 302, installing plumbing installations to the frame; step three 303, installing electrical installations to the frame; step four 304, installing a plurality of floor panels atop the base; step five 305, 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 306, connecting the plumbing installations to plumbing fixtures in the at least one bathroom and the kitchen; step seven 307, connecting the electrical installations to electrical fixtures in the at least one bathroom and the kitchen; step eight 308, installing a ceiling panel atop the at least four structure sides; step nine 309, installing a heating and cooling system and associated ductwork; step ten 310, performing quality testing and inspection; step eleven 311, packaging the core smart zone structure; and step twelve 312, 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 method 300 may 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 FIGS. 9A-11, which demonstrate the construction of an example building structure 200 and in particular, visually demonstrate a method 400 of constructing a building structure 200, a flowchart of which is shown in FIG. 12 and will be discussed in more detail below. It should be appreciated that the building structure 200 is not limited to the shape, size, or configuration shown here and various construction methods used with the present invention can produce a building structure 200 of any desired shape, size, or configuration. It should also be appreciated that the core smart zone structure 100 can be readily adapted to a multitude of construction types and methodologies and the building structure 200 shown and described in FIGS. 9A-11 is given as one illustrative example not meant to limit use of the core smart zone structure 100 in any way.

As shown here in these figures, the building structure 200 may include a foundation 201, the core smart zone structure 100 and a plurality of pre-fabricated insulated structure panels 121, 122 or other building construction materials. The foundation 201 may be configured for installation at a predetermined position at the on-site location (i.e., the desired final location of the building structure 200). In some embodiments, as shown here, the foundation 201 may 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 structure 100 and the plurality of insulated structure panels 121, 122 thereto. In particular, as shown in FIG. 9A, the foundation 201 may include a designated area 205 for receiving the core smart zone structure 100, after being transported to the on-site location subsequent fabrication thereof. As shown here, the designated area 205 may be located centrally to the building structure 200, making the core smart zone structure 100 the core module of the building structure 200 when installed thereon. FIG. 9B demonstrates the core smart zone structure 100 having been placed on the designated area 205 of the foundation 201.

As shown in FIGS. 10-11, in some embodiments, the plurality of pre-fabricated insulated structure panels 121, 122 may include a plurality of pre-fabricated insulated wall panels 121 and a plurality of pre-fabricated insulated roof panels 122. The insulated structure panels 121, 122 may preferably be precision cut off-site, enabling efficient and accurate on-site installation. The insulative properties of the pre-fabricated insulated structure panels 121, 122 may further contribute to high energy efficiency of the building structure 200.

As shown in FIG. 10, the plurality of pre-fabricated insulated wall panels 121 may be configured for installation at predetermined locations on the foundation 201 after being transported to the on-site location subsequent fabrication thereof. The plurality of pre-fabricated insulated wall panels 121 may form rooms within the building structure 200. For example, remaining rooms of the building structure 200 created via the plurality of pre-fabricated insulated wall panels 121 may 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 panels 121 may include, or may be arranged so as to provide, openings for windows and doors of the building 200.

In some embodiments, the plurality of pre-fabricated insulated wall panels 121 may be arranged at predetermined locations on the foundation 201 so as to form three separate partitioned living units. For example, one building structure 200 may 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 FIG. 11, the plurality of pre-fabricated insulated roof panels 122 may be configured for installation atop the plurality of pre-fabricated insulated wall panels 121 after having been transported to the on-site location subsequent fabrication thereof. The plurality of pre-fabricated insulated roof panels 122 may form a roof for the building structure 200.

In some examples, as shown here, the roof may be angled. Accordingly, a plurality of angled insulated panels 202 may be provided between the plurality of pre-fabricated insulated wall panels 121 and the plurality of pre-fabricated insulated roof panels 122 to support the plurality of pre-fabricated insulated roof panels 122. Further, trusses 206 may be erected in areas external to the plurality of pre-fabricated insulated wall panels 121 to support the roof panels 122.

Referring now to FIG. 12 which shows a flow diagram illustrating a method of constructing a building structure 400, according to an embodiment of the present disclosure. In particular, the method 400 may include one or more components or features of the building structure 200 and the core smart zone structure 100 as described above. As discussed above, this method 400 is provided as an example only and is not meant to limit use of the core smart zone structure 100 in any way. The core smart zone structure 100 is contemplated for use with various construction methods and building types.

As illustrated, the method 400 may include the steps of: step one 401, prefabricating the core smart zone structure; step two 402, prefabricating a plurality of insulated structure panels, as one of several construction methods which can adaptably use the core smart zone structure 100; step three 403, 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 404, transporting the core smart zone structure to the on-site location, which as above, may be via a single truck; step five 405, installing the core smart zone structure onto the designated area on the foundation; step six 406, transporting the plurality of insulated structure panels, or other preferred materials for chosen construction methodology, to the on-site location; step seven 407, 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 408, installing the plurality of insulated roof panels atop the plurality of wall panels, forming a roof for the building structure.

In some embodiments, step two 402 may involve precision cutting each insulated structure panels in an off-site controlled factory environment. Further, as discussed above, in some embodiments, the building structure 200 may include three separate partitioned living units. As such, in some embodiments, step seven 407 may 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 method 300 and method 400 can 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.

It should also be understood by one of skill in the art that the disclosed invention is described here in a few exemplary embodiments of many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom.

The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the relevant patent offices and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application.

Claims

1. A core smart zone structure comprising:

a frame including a base, at least four structure sides, and an interior defined thereby;

a plurality of floor panels installed atop the base;

a plurality of wall panels lining an outer and inner surface of each of the at least four structure sides;

a ceiling panel installed atop the at least four structure sides;

a kitchen defined in the interior of the frame;

at least one bathroom defined in the interior of the frame and separated from the kitchen by at least one inner wall;

a plurality of utility installations including electrical installations, plumbing installations, and a heating and cooling system; and

wherein the core smart zone structure is pre-fabricated off-site and configured for transportation to an on-site location after fabrication thereof for use in constructing a building structure.

2. The core smart zone structure of claim 1, further comprising a smart home technology system for controlling at least one of the plurality of utility installations.

3. The core smart zone structure of claim 2, wherein the smart home technology system includes a user terminal attached to one of the plurality of wall panels, enabling use of the smart home technology system.

4. The core smart zone structure of claim 1, wherein the frame is made from steel.

5. The core smart zone structure of claim 4, wherein the steel is cold rolled steel.

6. The core smart zone structure of claim 5, wherein the kitchen is located centrally within interior of the frame and defined by a pair of inner walls and a front and rear structure side of the at least four main structure sides.

7. The core smart zone structure of claim 6, wherein the at least one bathroom is partitioned from the kitchen via one of the pair of inner walls.

8. The core smart zone structure of claim 7, wherein the pair of inner walls are defined by the frame and each outer and inner surface of each of the pair of inner walls are lined by one of the plurality of wall panels.

9. The core smart zone structure of claim 8, wherein the electrical installations include at least: lighting, power outlets, switches and pre-cabling.

10. The core smart zone structure of claim 9, wherein the plumbing installations include separate hot and cold water lines supplying at least the kitchen and the at least one bathroom.

11. The core smart zone structure of claim 10, wherein the plumbing installations further include a blackwater discharge line.

12. The core smart zone structure of claim 11, wherein the plumbing installations further include a greywater discharge line.

13. A core smart zone structure pre-fabricated off-site and configured for transportation to an on-site location after fabrication thereof for use in constructing a building structure, the core smart zone structure comprising:

a generally cuboidal frame including a base, at least four structure sides, an interior defined thereby, and at least a pair of inner walls installed in the interior;

a plurality of floor panels installed atop the base;

a plurality of wall panels lining an outer and inner surface of each of the at least four structure sides and the pair of inner walls;

an inner and outer wall panel lining each pair of inner walls;

a ceiling panel installed atop the at least four structure sides;

a kitchen located centrally within interior of the frame and defined by the pair of inner walls and a front and rear structure side of the at least one four main structure sides;

at least one bathroom defined in the interior of the frame and partitioned from the kitchen via one of the pair of inner walls; and

a plurality of utility installations including:

electrical installations comprising at least: lighting, power outlets, switches and pre-cabling;

plumbing installations comprising at least: separate cold and hot water lines and at least one water discharge line; and

a heating and cooling system.

14. The core smart zone structure of claim 13, further comprising a smart home technology system for controlling at least one of the plurality of utility installations.

15. The core smart zone structure of claim 14, wherein the smart home technology system includes a user terminal attached to one of the plurality of wall panels, enabling use of the smart home technology system.

16. The core smart zone structure of claim 13, wherein the frame is made from steel.

17. The core smart zone structure of claim 16, wherein the steel is cold rolled steel.

18. The core smart zone structure of claim 17, wherein the at least one water discharge line includes at least one of a blackwater discharge line and a greywater discharge line.

19. A method of providing a core smart zone structure, the method comprising the steps of:

fabricating a frame including:

a base;

at least four structure sides attached to the base;

an interior defined by the at least four structure sides; and

at least a pair of inner walls in the interior to define a kitchen and at least one bathroom;

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 steps;

packaging the core smart zone structure; and

transporting the core smart zone structure to an on-site location.

20. The method of claim 19, wherein the entire core smart zone structure is transported to the on-site location on a single truck.