Manufacturing facility for production of standard size dwellings

• US 6,253,504 B1
• Filed: 11/14/1997
• Issued: 07/03/2001
• 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:
  US08/970,231
• Time in Patent Office: 1,327 Days
• Field of Search: 52/791, 521/43, 521/691, 521/692, 527/450.2, 527/451.3, 527/452
• US Class Current: 52/143
• CPC Class Codes: B28B 15/00 General arrangement or layout of plant ; Industrial outlines or plant installations
• 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
• CPC Class Codes: E04B 2001/3577 prefabricating a building and moving it as a whole to the erection site

Abstract

The 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 manufacturing facility for constructing standard size dwellings substantially in their entirety, said manufacturing facility being located proximate a location at which standard size dwellings are to be sited said manufacturing facility comprising:

a plurality of subassembly production lines, at least two of said subassembly production lines being used for constructing 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 consisting of;

walls, floors, roof, foundation base frame;

a dwelling assembly alley for assembling a partially assembled standard size dwelling therein;

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

wherein said standard size dwelling is assembled substantially in its entirety in said dwelling assembly alley using said predetermined subassemblies, which are incorporated into said partially assembled standard size dwelling.

2. The manufacturing facility of claim 1 wherein said hoisting means 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 one of said at least two said subassembly production lines.

3. The manufacturing facility of claim 1 further comprising:

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

4. The manufacturing facility of claim 2 wherein said enclosed structure has a wall, said dwelling assembly alley includes a doorway located in said wall of said enclosed structure and sized to enable transport elements, which are 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.

5. The manufacturing facility of claim 4 wherein said enclosed structure has a second wall, said dwelling assembly alley includes a second doorway located in said second wall of said enclosed structure to enable said transport elements, which are used to carry said standard size dwelling constructed within said enclosed structure, to enter said enclosed structure via said second doorway.

6. The manufacturing facility 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 dwelling assembly alley, said plurality of subassembly production lines comprise:

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

a second of said subassembly production lines, located adjacent said first subassembly production line, for constructing 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.

7. The manufacturing facility of claim 6 wherein said plurality of subassembly production lines further comprises:

a third of said subassembly production lines, located adjacent said second subassembly production line, for constructing 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

a fourth of said subassembly production lines, located adjacent said third subassembly production line, for constructing 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.

8. The manufacturing facility of claim 6 wherein said plurality of subassembly production lines further comprises:

a roofing subassembly production line, for constructing 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.

9. The manufacturing facility of claim 1 further comprising:

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

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

11. The manufacturing facility of claim 9 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.

12. The manufacturing facility of claim 11 wherein said hoisting element 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.

13. The manufacturing facility of claim 1 further comprising:

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

14. The manufacturing facility of claim 13 wherein said delivery alley includes a material storage area.

15. The manufacturing facility of claim 13 wherein said manufacturing facility further comprises a substantially enclosed structure, said delivery alley includes a first doorway located in a wall of said enclosed structure to enable delivery vehicles to enter said enclosed structure via said first doorway.

16. The manufacturing facility of claim 15 wherein said delivery alley includes 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.

17. The manufacturing facility of claim 13 wherein said hoisting means 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.

18. The manufacturing facility of claim 17 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.

19. The manufacturing facility of claim 1 wherein a first of said subassembly production lines is used to construct 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.

20. The manufacturing facility of claim 19 wherein a second of said subassembly production lines is used to construct 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.

21. The manufacturing facility of claim 20 wherein a third of said subassembly production lines is used to construct a 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.

22. The manufacturing facility of claim 19 wherein a second of said subassembly production lines is used to construct 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.

23. The manufacturing facility of claim 22 wherein a third of said subassembly production lines is used to construct 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.

24. The manufacturing facility of claim 23 wherein a fourth of said subassembly production lines is used to construct 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.

25. The manufacturing facility of claim 24 wherein said hoisting means located in said third subassembly production line transports 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.

26. The manufacturing facility of claim 23 wherein said hoisting means located in said second subassembly production line transports 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.

27. A manufacturing facility for constructing standard size, non-roadable dwellings, having length and width dimensions, substantially in their entirety in said 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, and comprising:

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

walls, floors, roof trusses, roof, foundation base frame;

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

hoisting means operational 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 at least one of the dimensional characteristics;

the smaller of said length and width dimensions being greater than 16 feet and being greater than one story in height; and

wherein said dwelling assembly alley provides a transport element for transporting 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 means 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.

28. The manufacturing facility of claim 27 wherein a first of said subassembly production lines is used to construct a floor subassembly comprising an integral base frame for placement on said 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.

29. The manufacturing facility of claim 28 wherein a second of said subassembly production lines is used to construct 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 lines to create a partially assembled standard size dwelling.

30. The manufacturing facility of claim 29 wherein a third of said subassembly production lines is used to construct 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.

31. The manufacturing facility of claim 30 wherein a fourth of said subassembly production lines is used to construct 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.

32. The manufacturing facility of claim 31 wherein said hoisting means located in said third subassembly production line transports 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.

33. The manufacturing facility of claim 30 wherein said hoisting means located in said second subassembly production line transports 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.

34. The manufacturing facility of claim 28 wherein a second of said subassembly production lines is used to construct 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.

35. The manufacturing facility of claim 34 wherein a third of said subassembly production lines is used to construct a second story wall assemblies for assembly on to said partially assembled full size dwelling located on said transport element, which is located in said dwelling assembly alley and juxtaposed said third subassembly production line.

36. The manufacturing facility of claim 27 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 dwelling assembly alley, said plurality of subassembly production lines comprise:

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

a second of said subassembly production lines, located adjacent said first subassembly production line, for constructing 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.

37. The manufacturing facility of claim 36 wherein said plurality of subassembly production lines further comprises:

a third of said subassembly production lines, located adjacent said second subassembly production line, for constructing a 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

a fourth of said subassembly production lines, located adjacent said third subassembly production line, for constructing 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.

38. The manufacturing facility of claim 36 wherein said plurality of subassembly production lines further comprises:

a roofing subassembly production line, for constructing 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.

39. A manufacturing facility for constructing standard size dwellings substantially in their entirety, said manufacturing facility being located proximate a location at which standard size dwellings are to be sited, comprising:

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

at least two subassembly production lines for constructing 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 consisting of;

walls, floors, roof;

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

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

40. The manufacturing facility of claim 39 wherein said at least two subassembly production lines comprises:

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

41. The manufacturing facility of claim 39 wherein said at least two subassembly production lines comprises:

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

42. The manufacturing facility of claim 39 wherein said foundation assembly production line produces an integral foundation base frame that circumscribes said standard size dwelling to support exterior walls of said standard size dwelling.

43. The manufacturing facility of claim 39 wherein said integral foundation base frame has a top surface thereof, said at least two subassembly production lines comprises:

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.

44. The manufacturing facility of claim 43 wherein said at least two subassembly production lines comprises:

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