U.S. patent application number 11/681052 was filed with the patent office on 2008-08-07 for home manufacturing facility.
Invention is credited to Matthew Priddy, James Rhodes.
Application Number | 20080184630 11/681052 |
Document ID | / |
Family ID | 39765010 |
Filed Date | 2008-08-07 |
United States Patent
Application |
20080184630 |
Kind Code |
A1 |
Rhodes; James ; et
al. |
August 7, 2008 |
HOME MANUFACTURING FACILITY
Abstract
The present invention relates to a facility for manufacturing
non-roadable buildings. The facility includes an enclosed area
having a roof and a plurality of bays for positioning the
non-roadable buildings therein, each of the plurality of bays is
configured to have one non-roadable building positioned therein and
being at least partially enclosed and separated from each other of
the plurality of bays. The facility further includes an exit
positioned adjacent each of the plurality of bays configured to
allow the non-roadable building positioned therein to pass
therethrough when the non-roadable building is substantially
complete and lifting devices positioned within the enclosed area
and configured to move elements for manufacturing of the
non-roadable building through the facility, including movement of
the elements to each of the plurality of bays.
Inventors: |
Rhodes; James; (Las Vegas,
NV) ; Priddy; Matthew; (Las Vegas, NV) |
Correspondence
Address: |
BELL, BOYD, & LLOYD LLP
P.O. BOX 1135
CHICAGO
IL
60690
US
|
Family ID: |
39765010 |
Appl. No.: |
11/681052 |
Filed: |
March 1, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60887696 |
Feb 1, 2007 |
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Current U.S.
Class: |
52/36.1 |
Current CPC
Class: |
E04B 2001/3577 20130101;
E04H 5/02 20130101 |
Class at
Publication: |
52/36.1 |
International
Class: |
E04H 1/00 20060101
E04H001/00 |
Claims
1. A facility for manufacturing non-roadable buildings, comprising
an enclosed area having a roof; a plurality of bays for positioning
said non-roadable buildings therein, each of said plurality of bays
configured to have one non-roadable building positioned therein and
being at least partially enclosed and separated from each other of
said plurality of bays; an exit positioned adjacent each of said
plurality of bays configured to allow said non-roadable building
positioned therein to pass therethrough when said non-roadable
building is substantially complete; and lifting means positioned
within said enclosed area and configured to move elements for
manufacturing of the non-roadable building through said facility,
including movement of said elements to each of said plurality of
bays.
2. A facility according to claim 1, wherein said lifting means
includes at least one of the following: an overhead crane, a gantry
crane, a floor crane and a fork lift.
3. A facility according to claim 1, further including a plurality
of subassemblies areas, each subassembly area dedicated to building
a predetermined portion of the non-roadable building.
4. A facility according to claim 3, wherein said elements for
manufacturing include said predetermined portion.
5. A facility according to claim 1, wherein said lifting means are
configured to pass over and between said plurality of bays.
6. A facility according to claim 1, wherein said facility includes
a dedicated area to move said lifting means.
7. A facility according to claim 1, wherein said non-roadable
buildings are at least two stories.
8. A facility according to claim 1, further comprising a vehicle
connection area proximate each said exit, said vehicle connection
area configured to allow a multiple piece transporter access to at
least two sides of said building, said multiple piece transporter
being capable of lifting and moving said non-roadable building to a
predetermined site.
9. A method of manufacturing non-roadable buildings, comprising the
steps of providing an enclosed area having a roof, said enclosed
area having a plurality or bays for positioning said non-roadable
buildings therein, each of said plurality of bays configured to
have one non-roadable building positioned therein and being at
least partially enclosed and separated from each other of said
plurality of bays; assembling said non-roadable buildings, such
that each of said non-roadable buildings is substantially complete,
using lifting means positioned within said enclosed area to move
elements for manufacturing of the non-roadable building through
said enclosed area, including movement of said elements to each of
said plurality of bays; and exiting said enclosed area through a
doorway configured to allow said substantially complete
non-roadable building to pass therethrough and adjacent each of
said plurality of bays.
10. A method according to claim 9, wherein said lifting means
includes at least one of the following: an overhead crane, a gantry
crane, a floor crane and a fork lift.
11. A method according to claim 9, further including the step of
providing a plurality of subassemblies areas, each subassembly area
dedicated to building a predetermined portion of the non-roadable
building.
12. A method according to claim 9, wherein said lifting means are
configured to pass over and between said plurality of bays.
13. A method according to claim 9, wherein said enclosed area
includes a dedicated area to move said lifting means.
14. A method according to claim 9, wherein said substantially
complete non-roadable buildings are at least two stories.
15. A method according to claim 9, wherein said step of exiting
said enclosed area includes connecting said building to a vehicle
at a vehicle connection area proximate said exit, said vehicle
connection area configured to allow a multiple piece transporter
access to at least two sides of said building, said multiple piece
transporter being capable of lifting and moving said non-roadable
building to a predetermined site.
16. An enclosed facility for manufacturing movable standard sized
dwellings, comprising: a plurality of bays configured to have one
movable standard sized dwelling manufactured and positioned
therein, each of said bays at least partially separated from each
of said other bays; a plurality of subassembly areas, each of said
subassembly areas configured to have a portion of the standard
sized dwelling built therein: lifting means to lift and move each
of said plurality of subassembly areas to each of said plurality of
bays; and an exit proximate each of said plurality of bays
configured to allow the standard sized dwelling to exit each bay;
wherein said standard sized dwellings are configured to be moved by
a multiple piece transport vehicle, capable of moving said standard
sized dwelling from an area adjacent said exit.
17. An enclosed facility according to claim 16, wherein said
standard sized dwellings include beams extending from a bottom area
thereof, each of said beams having a first end and a second end,
said first end adapted to couple to a first piece of said multiple
piece transport vehicle and said second end adapted to couple to a
second piece of said multiple piece transport vehicle.
18. An enclosed facility according to claim 16, wherein said
lifting means includes at least one of the following: an overhead
crane, a gantry crane, a floor crane and a fork lift.
19. An enclosed facility according to claim 16, wherein said
lifting means are configured to pass over and between said
plurality of bays.
20. An enclosed facility according to claim 16, further comprising
a dedicated area to move said lifting means.
21. An enclosed facility according to claim 16, wherein said
standard sized dwellings are at least two stories.
Description
RELATED APPLICATIONS
[0001] This application is related to co-pending U.S. patent
application Ser. No. 11/431,196 entitled "Building Transport
Device" and filed on May 9, 2006; Ser. No. 11/620,103 entitled
"Device and Method for Transporting a Load" and filed on Jan. 5,
2007; Ser. No. 11/559,229 entitled "Transport Device Capable of
Adjustment to Maintain Load Planarity" and filed on Nov. 13, 2006;
Ser. No. 11/620,560 entitled "Method and Apparatus for Mobile Stem
Wall" and filed on Jan. 5, 2007; and U.S. Provisional Patent
Application Ser. No. 60/887,696, entitled "METHOD AND APPARATUS FOR
INTEGRATED INVENTORY AND PLANNING" and filed on Feb. 1, 2007 the
entire contents of each of which is hereby incorporated by
reference.
BACKGROUND
[0002] Prefabricated buildings, such as commercial structures and
residential homes, have become a popular alternative to
"built-on-site" buildings. Prefabricated buildings include
manufactured buildings, wherein the building is built in a factory
setting, and prefabricated buildings, wherein the components of the
building are prefabricated and precut in a factory setting. Some
facilities are organized in an assembly line fashion to build the
individual components for a prefabricated home, such as the panels
and the framework. The components are precut at the factory and
shipped via truck to the site of the home for assembly.
[0003] However, prefabricated building systems are only able to
accommodate a single design or single model without having to
significantly change the assembly line(s), which can be very
expensive. Thus, consumers who desire to invest in prefabricated
homes are only provided with a limited number of design options set
by the manufacturers and lack the ability to select their own
custom, or mixed-model, designs.
[0004] Yet another significant drawback is that in order to ship
the buildings, the buildings must be split into appropriate sized
"modules" to fit on the back of a truck and fit within the typical
dimensions of a highway lane. In order to create appropriate sized
modules for shipping, a building is typically "forward engineered"
in parts, wherein each part is designed to fit within the maximum
allowable shipping limits, or envelope. In other words,
consideration of the size and the dimensions of the shipping
modules may override those of the consumer's desires in the design
of the building. This may place undesirable limitations on the
design of the building.
SUMMARY
[0005] The present invention relates to a facility for
manufacturing non-roadable buildings, including an enclosed area
having a roof and a plurality or bays for positioning the
non-roadable buildings therein, each of the plurality of bays
configured to have one non-roadable building positioned therein and
being at least partially enclosed and separated from each other of
the plurality of bays. The facility further includes an exit
positioned adjacent each of the plurality of bays configured to
allow the non-roadable building positioned therein to pass
therethrough when the non-roadable building is substantially
complete and lifting means positioned within the enclosed area and
configured to move elements for manufacturing of the non-roadable
building through the facility, including movement of the elements
to each of the plurality of bays.
[0006] In another embodiment, the present invention relates to a
method of manufacturing non-roadable buildings, including the steps
of providing an enclosed area having a roof, the enclosed area
having a plurality of bays for positioning the non-roadable
buildings therein, each of the plurality of bays configured to have
one non-roadable building positioned therein and being at least
partially enclosed and separated from each other of the plurality
of bays, assembling the non-roadable buildings using lifting means
positioned within the enclosed area to move elements for
manufacturing of the non-roadable building through the enclosed
area, including movement of the elements to each of the plurality
of bays, and exiting the enclosed area through a doorway configured
to allow the non-roadable building to pass therethrough and
adjacent each of the plurality of bays.
[0007] In another embodiment, the present invention relates to an
enclosed facility for manufacturing movable standard sized
dwellings, including a plurality of bays configured to have one
movable standard sized dwelling manufactured and positioned
therein, each of the bays being at least partially separated from
each of the other bays, a plurality of subassembly areas, each of
the subassembly areas configured to have a portion of the standard
sized dwelling built therein, lifting means to lift and move each
of the plurality of subassembly areas to each of the plurality of
bays, and an exit proximate each of the plurality of bays
configured to allow the standard sized dwelling to exit each bay.
Wherein the standard sized dwellings are configured to be moved by
a multiple piece transport vehicle, capable of moving the standard
sized dwelling from an area adjacent the exit.
[0008] Additional features and advantages are described herein, and
will be apparent from, the following Detailed Description and the
figures.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 is a top perspective view of a facility according to
one embodiment of the present invention with buildings positioned
within the bays;
[0010] FIG. 2 is a top perspective view of the facility of FIG. 1
with the roof removed;
[0011] FIG. 3 is an enlarged view of FIG. 2 showing one of the bays
and a hoisting device;
[0012] FIG. 4 is a top plan view of the facility shown in FIG.
2;
[0013] FIG. 5 is a side view in section of the facility of FIG. 4
taken along lines 5-5;
[0014] FIG. 6 is a side view of one end of the facility of FIG. 4
taken along lines 6-6; and
[0015] FIG. 7 is a top plan view of a second embodiment of the
present invention.
DETAILED DESCRIPTION
[0016] As illustrated in FIGS. 1-7, the present invention relates
to facility 10 for manufacturing buildings. The facility 10
includes a plurality of bays 12, a central area 14, which can
include a plurality of subassembly areas 16a-d and lifting or
hoisting device 18 to transport the subassemblies to each of the
bays 12. Preferably, the facility is positioned proximate to a
housing or building development. This allows the substantially
complete non-roadable home to avoid public roadways and travel
mainly on private or unrestricted roadways. Thus, the building is
not required to meet state roadway restrictions and can have any
suitable width, height or weight. However, it is noted that the
non-roadable buildings can be transported along public roads for
limited, authorized and/or monitored distances.
[0017] As shown in FIG. 1, the facility 10 is preferably an
enclosed or partially enclosed building that can have environmental
controls. The facility can have a roof and four sides, as in many
conventional facilities or it can have no roof, a partial roof or
as many or as few sides as desired and/or no or partial walls on a
side. Additionally, the facility can be divided into multiple
facilities or staging areas either within or without facility 10.
The facility 10 can be made from any suitable materials, such as
metal, wood, fabric or any other material that would allow the
workers and supplies located inside the facility to be protected
from any one or more of the sun, wind, precipitation, other
environmental elements, theft and/or any other undesirable
consequences.
[0018] As shown in FIGS. 1 and 2, the facility has a plurality of
building bays 12. The bays are each sized and configured to allow
at least a multi-storied (or a single storied) building 20 to be
built therein. Preferably, each bay is substantially square or
rectangular and sized and configured to allow a standard sized home
to be positioned and/or built therein. For example, each bay is
generally large enough to allow a building having a 60 foot by 40
foot configuration and enough room for personnel or equipment to
move around each side of the home. Although the bays are designed
for any suitable building, one embodiment includes building a
standard sized non-roadable home in each bay. The standard sized
homes are generally large single family homes have a square footage
of about 1600 ft or larger; however, a standard sized home can be
any home that is too large to be placed on a truck and transported
over public roads. However, each bay can be any suitable size
and/or configuration and have any suitable size or configuration of
buildings positioned and/or built therein, including various sized
bays to accommodate various sized and configured buildings.
[0019] Each bay preferably has an exit door 22 or area that allows
the building to be picked-up and transported away from the
facility. The exit doors or areas 22 of the bay can have any type
of suitable door or no door. For example, the door can be a garage
style door that can be closed to maintain a suitable or desired
interior climate and/or protect the building from outside or
exterior weather, theft or other undesirable elements. Furthermore,
the exit can be an opening with no door or covering sized and
configured to allow the buildings to exit therethrough.
[0020] Each bay is generally separated by a wall or partition 24.
The walls or partition 24 prefereably extends partially through the
facility and do not contact or abut the ceiling of the facility;
however, wall 24 can extend to any suitable height, including to
the ceiling, thus, completely separating the bays or, if desired,
the bays can have no walls separating them.
[0021] Walls 24 can be formed of any suitable material and have any
suitable thickness. For example, the walls can be relatively thin
just separating each building bay or they can be thick enough to
house a closet, restroom or other facility.
[0022] Each bay 12 can be separated from the central area 14, if
desired using walls or partitions (not shown). As with the walls
24, the walls separating the bay from the central area can be full
height, partial height, thin, thick, have storage or other
facilities therein, or by constructed in any suitable manner and
have any suitable size and configuration.
[0023] As shown in FIGS. 3 and 4, the facility includes a hoisting
device 18. Prefereably the hoisting device 18 is an overhead hoist
that can move longitudinally through the facility using rails 26
and 28. The rails preferably run the entire length or substantially
the entire length of the facility 10. The rails can be held
overhead by columns, or any other suitable structure, including but
not limited to the internal structure of the facility and/or
specifically designed internal structure. This configuration of the
rails allows the hook 30 to traverse the entire facility and access
each of the plurality of bays and the each of the subassembly
areas. Additionally, the hoist 18 can traverse the facility
laterally using rail 32. Rail 32 preferably spans between rails 26
and 28, thus allowing hook 30 to move laterally within or over area
14 and move between the opposing bay areas.
[0024] Furthermore, hook 30 can move up and down relative to rail
32. Preferably, hook 32 can extend to the floor of the facility or
substantially to rail 32. This allows the hoisting device to pick
up material, a desirable structure, element or other device and
move it anywhere in the facility. It is noted that the hoisting
device can be any suitable hoist or lifting device (e.g., an
overhead crane, a gantry crane, a floor crane and a fork lift or
any other suitable device) and can traverse any suitable area of
the facility. Additionally, hoisting device can have any suitable
configuration or construction, move at any suitable speed or in any
suitable limited or unlimited areas around the facility.
[0025] Preferably, the hoisting device 18 is motorized and in three
dimensions. In other words, hook 30 is driven by a motor or a
plurality of motors that move the hook laterally and longitudinally
relative to the subassembly areas and up and down relative the
floor of the facility. The hook can be operated by manual controls
and an operator that moves the hook over or near a desired portion
of the building or construction item and lowers the hook to pick up
the item. The user or operator can them lift and move the item to
the desired area of the facility and lower the item. Furthermore,
the hoisting device 18 can be fully automated using any suitable
computer control system. It is necessary for the hoisting device to
be motorized. The device can be manually operated if desired.
[0026] Central area 14 is generally divided into a plurality of
areas 16a-d. Each subassembly area is generally designed to build a
specific portion of the non-roadable standard sized building. For
example, specific areas can be used to build floors, walls,
ceilings, foundations, or any other portion of a house desired.
Areas can be specifically used for internal finishing, such as,
plumbing, electrical, drywall, painting, wood trim, etc. There can
be any suitable number of subassembly areas desired and some or all
of the areas can have multiple purposes, if desired.
[0027] The facility 10 has a first opening or exit 34 and a second
opening or exit 36 in the central area 14. Each exit 34 and 36 can
have a door or covering to protect the interior of the facility, if
desired. Exit 34 is preferably sized and configured to allow a
standard sized non-roadable building to pass therethrough. However,
it is noted that since each bay has an exit for the non-roadable
buildings, each exit 34 and 36 do not necessarily need to be
configured to allow the buildings to pass therethrough. Each
building can be configured to allow a vehicle or truck to pass
through such that workers, material and/or subassemblies or any
other desired element used in the facility can pass therethrough.
Furthermore, it is not necessary to have a door at each end or at
either end. If desired, there can be one door or no doors or as
many doors each end is capable of having therein. If no doors are
present, one or any number of the exit doors for the bays can be
used to pass workers, materials or anything else into and out of
the facility.
Operation
[0028] Generally, materials are brought to the facility 10 using a
truck or other vehicle, which can enter the facility using one of
the first exit 34 or the second exit 36. The materials for each
specific subassembly area are offloaded and the truck or vehicle
moves through the facility offloading material until it exits the
facility 10.
[0029] At each subassembly area 16a-e, the specific portion or
portion of the house or building are built. For example, one
subassembly area can build a floor assembly, another can build
walls and another can build the ceilings. Multiple of each portion
or subassembly can be built and stored in the specific subassembly
area, thus allow the workers to efficiently build subassemblies
without each house being built from the ground up, as done in
conventional stick building. For example, the roof subassembly area
can build multiple roofs and store the roofs in the subassembly
area or other suitable area or even in another area within or
without the facility. Once a house in a bay is ready, a roof can be
attached. Thus, multiple roofs can be built before the walls or
floors of the building are built or attached to the building
10.
[0030] Preferably, the floor or base of the facility is positioned
within the facility. The base is generally built such that it can
withstand movement from the facility to a predetermined position
adjacent the facility for final location. The base can be formed
from concrete, steel wood or any other suitable material. The base
is preferably built in the base subassembly area and once completed
moved using the hoisting device to an open bay. However, it is
noted that the base (or any other subassembly) can be built in a
bay, rather than moved. Additionally, the base can be built as
described in related U.S. Patent Applications discussed and
incorporated by reference above. Thus allowing a specially designed
vehicle to move the building. Please note that it is not necessary
to move the building using a specially designed vehicle or as
recited in the related applications.
[0031] Next the first floor walls can be moved from their specific
subassembly area using the hoisting device to a bay. The walls are
then attached to the floor. The walls can be finished with trim and
drywall either in the wall subassembly area, the bay, the
predetermined site for the home or in any other suitable place. The
building is then built using the subassemblies until finished. The
building can be a one, two or more story building and can be any
suitable building structure. Preferably, the building is a standard
sized substantially complete non-roadable house, but the building
can be any suitable structure.
[0032] Once the building 10 is substantially complete, the building
is moved through the adjacent facility exit. The building can be
moved using any conventional moving means or devices. For example,
the house can be moved using a dolly, a conveyor or any other
structure. Once moved out of the facility, the building can be
moved to a predetermined final position. The building can be moved
using any suitable device, such as a truck or other device. One
suitable device is a two vehicle transporter described in the U.S.
Patent Applications discussed above, the entire contents of which
have already been incorporated by reference. Generally this vehicle
can have each of its two vehicles straddle the building, engage the
building, pick the building up and move the building to the desired
location; however, the building can be designed in any suitable
manner and is not necessarily transported with the two piece
vehicle.
[0033] If desired, the bays can be sized and configured to allow
the two piece vehicle to enter the facility and attach to the
building in the bays, thus eliminating the need to have a device to
move the building outside of the bays. This movement would be
accomplished by the vehicle itself.
[0034] The operation described herein is exemplary and is not meant
to limit the facility, but rather facilitate the understanding of
the invention and the facility can be operated in any manner
desired.
[0035] FIG. 7 illustrates a facility 100 according to a second
embodiment of the present invention. Facility 100 includes a
plurality of subassembly lanes or areas 102a-e, a hoisting system
and a plurality of bays 106.
[0036] Subassembly lanes 102a-e are substantially similar to the
subassembly areas described above. That is, the subassembly areas
are preferably designed to build a specific portion of the
non-roadable standard sized building. For example, specific areas
can be used to build floors, walls, ceilings, foundations, or any
other portion of a house desired. Areas can be specifically used
for internal finishing, such as, plumbing, electrical, drywall,
painting, wood trim, etc. There can be any suitable number of
subassembly areas desired and some or all of the areas can have
multiple purposes, if desired. Supplies, materials or the like can
be delivered to the subassemblies through a suitable door,
similarly to as described above or in any suitable manner.
[0037] Bays 106 are substantially similar to the bays described
above and any description thereof is applicable to bays 106. Each
bay preferably has an exit 108 that allows the building 110
positioned therein to be moved or transported to a predetermined
site. As with the bays described above, the bays can be sized and
configured to allow a standard sized non-roadable home therein or
any other suitable building. Furthermore, each bay or any number of
bays can be sized and configured to allow a two piece transport
vehicle to enter the facility and straddle the building. The
vehicle can then attach itself to the building and transport the
building to a predetermined site, such as a foundation or area for
permanent placement of the building.
[0038] The building bays 106 can have partition or walls 107,
substantially similar to the walls described above. That is, the
can extend from the floor to the ceiling or only partially to the
ceiling, leaving a gap or opening between the wall 107 and the
ceiling. Such an opening or gap could be configured to allow the
hoisting system to pass over each building bay to the next bay, if
desired.
[0039] The buildings 110 exit the facility and are transported to a
predetermined site using any of the methods or devices described
above or in any other suitable manner.
[0040] Hoisting system can include any suitable lifting device,
including the lifting devices described above. In facility 100, the
lifting system includes means, such as rails or other suitable
systems, to allow the hoist to travel from any one of the
subassembly areas to any one of the building bays.
[0041] As shown in FIG. 7, the facility can have a dedicated area
112 for moving the hoisting system. Such a dedicated area would
allow the subassemblies to move through the facility without
endangering workers or other materials in the facility. The
subassemblies could be moved through this area at any suitable
height, including but not limited to at or near ground level.
[0042] The operation of facility 100 is substantially similar to
the operation of facility 10 and any description thereof is
suitable for the description of facility 100, unless otherwise
specifically differentiated from herein.
[0043] It should be understood that various changes and
modifications to the presently preferred embodiments described
herein will be apparent to those skilled in the art. Such changes
and modifications can be made without departing from the spirit and
scope of the present subject matter and without diminishing its
intended advantages. It is therefore intended that such changes and
modifications be covered by the appended claims.
* * * * *