Prefabricated housing components

Abstract

A prefabricated housing component that includes at least one casting having a wall portion, a floor portion, a ceiling portion, wherein the wall portion, floor portion and ceiling portion cooperate to form an interior space, and a cabinet portion including a recessed portion within the interior space. The prefabricated housing component further includes a framework surrounding the casting, wherein the framework provides structural rigidity thereto.

The invention claimed is:  
     
         1 . A prefabricated housing component, comprising: 
 at least one casting, comprising: 
 a wall portion;  
 a floor portion;  
 a ceiling portion, wherein the wall portion, floor portion and ceiling portion cooperate to form an interior space; and  
 a cabinet portion including a recessed portion located within the interior space; and  
   a framework surrounding the casting, wherein the framework provides structural rigidity thereto.    
     
     
         2 . The prefabricated housing component of  claim 1 , wherein the casting comprises fiberglass.  
     
     
         3 . The prefabricated housing component of  claim 2 , wherein the casting comprises a resin.  
     
     
         4 . The prefabricated housing component of  claim 3 , wherein the resin is fire retardant.  
     
     
         5 . The prefabricated housing component of  claim 1 , wherein the casting comprises plastic.  
     
     
         6 . The prefabricated housing component of  claim 1 , wherein the at least one casting includes a first casting and a second casting matable theretogether; and further comprising: 
 an alignment portion including an alignment pin and an alignment aperture.    
     
     
         7 . The prefabricated housing component of  claim 1 , wherein the framework is fixedly attached to the casting.  
     
     
         8 . The prefabricated housing component of  claim 6 , wherein the framework includes at least one stud fixedly attached to the casting via resin and fiberglass.  
     
     
         9 . The prefabricated housing component of  claim 7 , further comprising: 
 at least one support rib attached to the exterior of the casting.    
     
     
         10 . The prefabricated housing component of  claim 9 , further comprising: 
 at least one bracket securing the at least one support rib to a stud of the framework.    
     
     
         11 . The prefabricated housing component of  claim 10 , wherein the at least one bracket is adjustable.  
     
     
         12 . The prefabricated housing component of  claim 1  further comprising: 
 at least one support rib attached to the exterior of the casting.  
 
     
     
         13 . The prefabricated housing component of  claim 1 , wherein the castings comprise a stress relieving material encased in layers of resin and fiber material.  
     
     
         14 . The prefabricated housing component of  claim 12 , wherein the stress relieving material includes cardboard.  
     
     
         15 . The prefabricated housing component of  claim 14 , wherein the stress relieving material includes wood.  
     
     
         16 . The prefabricated housing component of  claim 1 , wherein the floor portion of the casting comprises a rigid core material surrounded by layers of resin and fiber material.  
     
     
         17 . The prefabricated housing component of  claim 18 , wherein the core material is wood.  
     
     
         18 . The prefabricated housing component of  claim 1 , wherein a lip portion of the casting surrounding the recessed portion includes a layer of wood material.  
     
     
         19 . The prefabricated housing component of  claim 1 , further comprising: 
 a cabinet insert, wherein the recessed portion of the cabinet portion is cutout to receive the cabinet insert.    
     
     
         20 . The prefabricated housing component of  claim 22 , wherein a lip portion of the casting surrounding the recessed portion is hook shaped, and wherein an edge of an insert received within the recessed portion is hook shaped, such that the lip portion of the casting and the edge of the insert interlock.  
     
     
         21 . The prefabricated housing component of  claim 1 , wherein the floor portion is recessed for receiving a flooring material.  
     
     
         22 . The prefabricated housing component of  claim 1 , wherein the composite casting further comprises a feature selected from a group consisting of a light mount recess, a sculpted edge, a sculpted joint and a sculpted corner.  
     
     
         23 . The prefabricated housing component of  claim 22 , wherein the sculpted edges, sculpted joints and sculpted corners comprise rounded edges, rounded joints and rounded corners.  
     
     
         24 . The prefabricated housing component of  claim 1 , further including: 
 a trolley assembly detachably connected to the housing component and adapted to rollably support the housing component.    
     
     
         25 . The prefabricated housing component of  claim 1 , further including: 
 a drain pan attached to the floor portion and adapted to collect water that leaks through the floor proximate the drain pan.    
     
     
         26 . A method of manufacturing a prefabricated housing component comprising the steps of: 
 applying a composite material to a mold that includes a wall portion, a ceiling portion and a floor portion;    allowing the composite material to at least partially cure, thereby resulting in a casting;    removing the casting from within the mold;    inserting the casting into a cavity as defined by a framework; and    securing the casting to the framework.    
     
     
         27 . The method of manufacturing a prefabricated housing component of  claim 24 , further comprising: 
 securing a support rib to an exterior of the casting prior to inserting the casting.    
     
     
         28 . The method of manufacturing a prefabricated housing component of  claim 27 , further comprising: 
 securing the rib to the framework.    
     
     
         29 . The method of manufacturing a prefabricated housing component of  claim 28 , wherein the step of securing the rib to the framework includes securing the rib to the framework with an L-shaped bracket.  
     
     
         30 . The method of manufacturing a prefabricated housing component of  claim 29 , wherein the step of securing the rib to the framework is accomplished prior to the composite material fully curing.  
     
     
         31 . The method of manufacturing of a prefabricated housing component  claim 26 , wherein the step of applying a composite material comprises applying corrugated cardboard to the mold.  
     
     
         32 . The method of manufacturing a prefabricated housing component of  claim 26 , wherein the step of applying a composite material comprises applying balsa wood to the mold.  
     
     
         33 . The method of manufacturing a prefabricated housing component of  claim 26 , wherein the mold defines a recessed portion within an interior of the casting.  
     
     
         34 . The method of manufacturing a prefabricated housing component of  claim 33 , further including: 
 cutting out a portion of the recessed portion, thereby forming an aperture within the recessed portion;    providing an insert portion; and    inserting the insert portion into the aperture within the recessed portion.    
     
     
         35 . The method of manufacturing a prefabricated housing component of  claim 26 , wherein the step of securing the casting to the framework comprises bonding the framework to the casting with a composite material.  
     
     
         36 . The method of manufacturing a prefabricated housing component of  claim 26 , further including: 
 supporting the framework by at least one trolley assembly, thereby providing clearance below the housing component.