Method of production of standard size dwellings

• US 6,000,192 A
• Filed: 11/14/1997
• Issued: 12/14/1999
• Est. Priority Date: 07/14/1995
• Status: Expired due to Term

• Current Assignee: INTELLECTUAL PROPERTY, LLC
• Original Assignee: Cohen Brothers Homes, LLC
• Inventors: Cohen, Roger Blair, Cohen, David Leslie
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): Wilkens, Kevin D.
• Application Number:
  US08/970,181
• Time in Patent Office: 760 Days
• Field of Search: 52/79.1, 52/169.1, 52/169.2, 52/143, 52/745.2, 52/745.13, 52/745.02
• US Class Current: 52/745.2
• CPC Class Codes: B28B 15/00 General arrangement or layout of plant ; Industrial outlines or plant installations
• CPC Class Codes: B28B 15/002 Mobile plants, e.g. on vehicles or on boats
• CPC Class Codes: E04B 1/35 Extraordinary methods of construction, e.g. lift-slab, jack-block E04B1/34 takes precedence; falsework, shuttering for shaping walls, floors, ceilings or roofs in situ E04G11/04; conveying or assembling of building materials E04G21/00; working measures on existing buildings E04G23/00

Abstract

The method of manufacturing standard size dwellings using a movable manufacturing facility brings standard size home building comprehensively within a controlled factory environment. The main structure of the movable manufacturing facility is sufficiently tall to allow assembly and movement of standard size homes within. Multiple independent production lines are established to each produce portions of the dwelling in the form of subassemblies. Finishes, cabinets, appliances, roofs, paint, etc. are installed in the partially completed dwellings prior to houses leaving the production floor. The movable manufacturing facility allows a standard size home under construction to be advanced via a transport element from one production line to the next until complete. The completed homes are subsequently transported on the transport element over a controlled access roadway to individual sites with pre-constructed foundations specifically designed to accept these standard size dwellings. The standard size house can be relocated from the transport element and placed directly onto the foundation. High capacity hoisting, such as clear span bridge cranes, are the key to material handling and transportation on the production lines in the movable manufacturing facility. A drive through alley large enough to accommodate semi-trucks with loaded trailers may be located within the main structure of the movable manufacturing facility.

Claims

1. A method for constructing standard size dwellings substantially in their entirety using a manufacturing facility that includes a plurality of dwelling subassembly production lines and a dwelling assembly alley, said manufacturing facility being located proximate a location at which standard size dwellings produced in said manufacturing facility are to be sited comprising the steps of:

constructing, in said manufacturing facility, predetermined subassemblies for said standard size dwelling in at least two of said plurality of subassembly production lines, each of said predetermined subassemblies comprising a structural section of said standard size dwelling, from the class of structural sections including;

walls, floors, roof, foundation base frame;

transporting, using hoisting elements operational in each of said at least two subassembly production lines, said constructed predetermined subassemblies to said dwelling assembly alley for incorporation into a partially assembled standard size dwelling being assembled in said dwelling assembly alley; and

transporting said partially assembled standard size dwelling through said dwelling assembly alley to said at least two subassembly production lines, said standard size dwelling being assembled, substantially in its entirety, using said predetermined subassemblies, which are incorporated into said partially assembled standard sized dwelling when said partially assembled standard sized dwelling is positioned in dwelling assembly alley opposite each successive one of said at least two subassembly production lines.

2. The method of manufacturing of claim 1 wherein at least one of said hoisting elements comprises an overhead crane that traverses a one of said at least two subassembly production lines and a section of said dwelling assembly alley adjacent said a one of said at least two subassembly production lines.

3. The method of manufacturing of claim 1 further comprising the step of:

providing at least one transport element movable through said assembly alley for supporting and moving said standard size dwelling.

4. The method of manufacturing of claim 1 further comprising the step of:

receiving, in a delivery alley located substantially proximate to said at least two subassembly production lines, deliveries of materials used in construction of said standard size dwelling.

5. The method of manufacturing of claim 4 wherein said delivery alley includes a material storage area.

6. The method of manufacturing of claim 4 wherein said hoisting elements in each of said at least two subassembly production lines comprises at least one movable crane that traverses said subassembly production line and a section of said dwelling assembly alley adjacent said subassembly production line.

7. The method of manufacturing of claim 6 wherein said movable crane in each of said at least two subassembly production lines also traverses a section of said delivery alley adjacent said subassembly production line.

8. The method of manufacturing of claim 1 wherein said method further comprises:

constructing an enclosed structure of interior height sufficient to assemble a standard size dwelling therein.

9. The method of manufacturing of claim 8 wherein said dwelling assembly alley is of interior height sufficient to assemble a standard size dwelling therein.

10. The method of manufacturing of claim 8, wherein said enclosed structure has a wall, said method further comprising the step of:

providing a doorway located in said wall of said enclosed structure and sized to enable transport elements used to carry said standard size dwelling constructed within said enclosed structure to exit said enclosed structure transporting a substantially completed standard size dwelling via said doorway.

11. The method of manufacturing of claim 10 wherein said enclosed structure has a second wall, said method further comprising the step of:

providing a second doorway located in said second wall of said enclosed structure to enable transport elements used to carry said standard size dwelling constructed within said enclosed structure to enter said enclosed structure via said second doorway.

12. The method of manufacturing of claim 8 further comprising providing a first doorway located in a wall of said enclosed structure to enable delivery vehicles to enter said enclosed structure via said first doorway.

13. The method of manufacturing of claim 12 further comprising providing a second doorway located in a second wall of said enclosed structure to enable delivery vehicles to exit said enclosed structure via said second doorway.

14. The method of manufacturing of claim 8 wherein said enclosed structure comprises a plurality of bents, each supported by a plurality of support columns, a plurality of said bents and associated plurality of support columns being oriented between adjacent subassembly production lines.

15. The method of manufacturing of claim 14 wherein at least one of said hoisting elements comprises an overhead crane which operates on a set of rails, which rails are supported by said associated plurality of support columns oriented between adjacent subassembly production lines.

16. The method of manufacturing of claim 1 wherein said plurality of subassembly production lines are oriented substantially parallel to and juxtaposed to at least one other subassembly production line and orthogonal to said assembly alley, said method further comprises:

constructing, in a first of said subassembly production lines, a floor subassembly comprising an integral base frame for placement on a transport element located in said dwelling assembly alley; and

constructing, in a second of said subassembly production lines, located adjacent said first subassembly production line, a plurality of panelized wall assemblies for assembly on to said floor subassembly located on said transport element located in said assembly alley.

17. The method of manufacturing of claim 16, further comprising the steps of:

constructing, in a third of said subassembly production lines, located adjacent said second subassembly production line, a plurality of second story wall assemblies for assembly in said standard size dwelling located on said transport element located in said dwelling assembly alley; and

constructing, in a fourth of said subassembly production lines, located adjacent said third subassembly production line, a roof subassembly for assembly on to said standard size dwelling located on said transport element located in said dwelling assembly alley.

18. The method of manufacturing of claim 16, further comprising:

constructing, in a roofing subassembly production line located adjacent said second subassembly production line, a roof subassembly for assembly on to said standard size dwelling located on said transport element located in said dwelling assembly alley.

19. The method of manufacturing of claim 1 further comprising the step of:

constructing, in a first of said subassembly production lines, a floor subassembly comprising an integral base frame for placement on a transport element located in said dwelling assembly alley and juxtaposed said first subassembly production line, which transport element transports said partially assembled standard size dwelling through said dwelling assembly alley.

20. The method of manufacturing of claim 19 further comprising the step of:

constructing, in a second of said subassembly production lines, a plurality of panelized wall assemblies for assembly on to said floor subassembly located on said transport element, which is located in said dwelling assembly alley and juxtaposed said second subassembly production line.

21. The method of manufacturing of claim 20 further comprising the step of:

constructing, in a third of said subassembly production lines, a roof subassembly for assembly on to said partially assembled standard size dwelling located on a transport element located in said dwelling assembly alley and juxtaposed to said third subassembly production line.

22. The method of manufacturing of claim 20 further comprising the step of:

constructing, in a third of said subassembly production lines, second story wall subassemblies, for installation in the partially assembled standard size dwelling located on said transport element located in said dwelling assembly alley and juxtaposed to said third subassembly production line.

23. The method of manufacturing of claim 22 further comprising the step of:

transporting, using a one of said hoisting elements which is located in said second subassembly production line, finish elements to be installed in a first floor of said standard size dwelling prior to said transport element relocating said standard size dwelling from a position in said dwelling assembly alley opposite said second subassembly production line to a position opposite said third subassembly production line.

24. The method of manufacturing of claim 22 further comprising the step of:

constructing, in a fourth of said subassembly production lines a roof subassembly for assembly on to said partially assembled standard size dwelling located on said transport element located in said dwelling assembly alley and juxtaposed to said fourth subassembly production line.

25. The method of manufacturing of claim 24 further comprising the step of:

transporting, using a one of said hoisting elements which is located in said third subassembly production line, finish elements to be installed in a second floor of said standard size dwelling prior to said transport element relocating said standard size dwelling from a position in said dwelling assembly alley opposite said third subassembly production line to a position opposite said fourth subassembly production line.

26. A method for constructing standard size dwellings substantially in their entirety in a manufacturing facility, said manufacturing facility being located proximate a location at which standard size dwellings produced in said manufacturing facility are to be sited after exiting said manufacturing facility, comprising the steps of:

constructing, in said manufacturing facility, predetermined subassemblies for said standard size dwelling in at least two subassembly production lines, each of said predetermined subassemblies comprising a structural section of said standard size dwelling, from the class of structural sections including;

walls, floors, roof, foundation base frame;

assembling in a dwelling assembly alley located substantially proximate to said at least two subassembly production lines, a partially assembled standard size dwelling therein;

operating hoisting elements in said at least two subassembly production lines for transporting said constructed predetermined subassemblies from said at least two subassembly production lines to said dwelling assembly alley to install said constructed predetermined subassemblies into a partially assembled standard size dwelling located therein, which partially assembled standard size dwelling is non-roadable by having length and width dimensions, with the smaller of said length and width dimensions being greater than 14 feet and being greater than one story in height; and

transporting in said dwelling assembly alley said partially assembled standard size dwelling while said standard size dwelling is assembled from said predetermined subassemblies by respectively incorporating said predetermined subassemblies into said partially assembled standard size dwelling using said hoisting elements when said partially assembled standard size dwelling is positioned in said assembly alley opposite a corresponding one of said plurality of subassembly production lines until said partially assembled standard size dwelling is assembled substantially in its entirety.

27. The method of claim 26 wherein said step of constructing comprises:

orienting said plurality of subassembly production lines substantially parallel to and juxtaposed to at least one other subassembly production line and orthogonal to said dwelling assembly alley, said method further comprising;

constructing in a first of said subassembly production lines a floor subassembly comprising an integral base frame for placement on a transport element, which is located in said dwelling assembly alley; and

constructing in a second of said subassembly production lines, located adjacent said first subassembly production line, a plurality of panelized wall assemblies for assembly on to said floor subassembly located on said transport element, which is located in said assembly alley to produce a partially assembled standard size dwelling.

28. The method of claim 27 wherein said method further comprises:

constructing in a third of said subassembly production lines, located adjacent said second subassembly production line, second story wall assemblies for assembly on to said partially assembled standard size dwelling located on said transport element, which is located in said dwelling assembly alley; and

constructing in a fourth of said subassembly production lines, located adjacent said third subassembly production line, a roof subassembly for assembly on to said partially assembled standard size dwelling which is located on said transport element located in said dwelling assembly alley.

29. The method of claim 27 wherein said method further comprises:

constructing in a roofing subassembly production line, a roof subassembly for assembly on to said partially assembled standard size dwelling located on said transport element, which is located in said dwelling assembly alley.

30. The method of claim 26 wherein said step of constructing comprises:

constructing, in a first of said subassembly production lines, a floor subassembly comprising an integral base frame for placement on a transport element, which is located in said dwelling assembly alley and juxtaposed said first subassembly production line, which transport element transports said partially assembled standard size dwelling through said dwelling assembly alley.

31. The method of claim 30 wherein said step of constructing comprises:

constructing, in a second of said subassembly production lines, a plurality of panelized exterior wall assemblies and interior walls for assembly on to said floor subassembly located on said transport element, which is located in said dwelling assembly alley and juxtaposed to said second subassembly production line, to produce a partially assembled standard size dwelling.

32. The method of claim 31 wherein said step of constructing further comprises:

constructing, in a third of said subassembly production lines, second story wall assemblies for assembly on to said partially assembled standard size dwelling located on said transport element, which is located in said dwelling assembly alley and juxtaposed said third subassembly production line.

33. The method of claim 30 wherein said step of constructing further comprises:

constructing, in a second of said subassembly production lines, a plurality of panelized wall assemblies for assembly on to said floor subassembly located on said transport element, which is located in said dwelling assembly alley and juxtaposed said second subassembly production line, to create a partially assembled standard size dwelling.

34. The method of claim 33 wherein said step of constructing further comprises:

constructing, in a third of said subassembly production lines, second story wall subassemblies, for installation in the partially assembled standard size dwelling located on said transport element, which is located in said dwelling assembly alley and juxtaposed said third subassembly production line.

35. The method of claim 34 wherein said step of constructing further comprises:

constructing, in a fourth of said subassembly production lines, a roof subassembly for assembly on to said partially assembled standard size dwelling located on said transport element, which is located in said dwelling assembly alley and juxtaposed said fourth subassembly production line.

36. The method of claim 34 wherein said step of operating comprises:

transporting, via a one of said hoisting elements which is located in said second subassembly production line, finish elements to be installed in a first floor of said partially assembled standard size dwelling prior to said transport element relocating said partially assembled standard size dwelling from a position in said dwelling assembly alley opposite said second subassembly production line to a position opposite said third subassembly production line.

37. The method of claim 36 wherein said step of operating further comprises:

transporting via a one of said hoisting elements which is located in said third subassembly production line, finish elements to be installed in a second floor of said partially assembled standard size dwelling prior to said transport element relocating said partially assembled standard size dwelling from a position in said dwelling assembly alley opposite said third subassembly production line to a position opposite said fourth subassembly production line.

38. A method for constructing standard size dwellings substantially in their entirety at a manufacturing facility, said manufacturing facility being located proximate a location at which standard size dwellings produced by said manufacturing facility are to be sited, comprising the steps of:

constructing, in a foundation assembly production line, an integral foundation base frame that supports load bearing walls of said standard size dwelling;

constructing, in at least two subassembly production lines, predetermined subassemblies for said standard size dwelling, each of said predetermined subassemblies comprising a structural section of said standard size dwelling, from the class of structural sections including;

walls, floors, roof;

assembling, in a dwelling assembly alley located substantially proximate to said at least two subassembly production lines, a partially assembled standard size dwelling therein using said predetermined subassemblies, which are incorporated into said partially assembled standard sized dwelling until said partially assembled standard size dwelling is assembled substantially in its entirety; and

operating hoisting elements in each of said at least two subassembly production lines for transporting said constructed predetermined subassemblies to said dwelling assembly alley for incorporation into said partially assembled standard size dwelling being assembled therein, with said hoisting elements transporting at least a subset of load bearing ones of said predetermined subassemblies for direct connection to said integral foundation base frame.

39. The method of claim 38 wherein said step of constructing in at least two subassembly production lines comprises:

operating a floor subassembly production line for assembly of floor subassemblies for incorporation directly into said integral foundation base frame.

40. The method of claim 38 wherein said step of operating at least two subassembly production lines comprises:

operating a load bearing wall subassembly production line for assembly of load bearing wall subassemblies for incorporation into said partially assembled standard sized dwelling by structural attachment to said integral foundation base frame.

41. The method of claim 38 wherein said step of operating a foundation assembly production line comprises:

producing an integral foundation base frame that circumscribes said standard size dwelling to support exterior walls of said standard size dwelling.

42. The method of claim 38 wherein said integral foundation base frame has a top surface thereof, said step of operating at least two subassembly production lines comprises:

operating a floor subassembly production line for assembly of floor subassemblies for incorporation directly into said integral foundation base frame absent being placed directly on said top surface of said integral foundation base frame.

43. The method of claim 42 wherein said step of operating at least two subassembly production lines comprises:

operating a load bearing wall subassembly production line for assembly of load bearing wall subassemblies for incorporation into said partially assembled standard sized dwelling by structural attachment to said top surface of said integral foundation base frame.