Modular housing system

Abstract

A modular production system and method for producing wall panels of a modular building. The system includes a worktable, a plurality of telescoping tools mounted over the worktable, an overhead tram disposed adjacent the worktable, and a plurality of material supply bridges movably supported on the overhead tram so as to be movable over the worktable. The method of manufacturing a panel of a modular structure includes moving the first material supply bridge over a worktable to place panels of sheeting on the worktable, and then moving a second material supply bridge over the worktable to place steel members for the construction of a steel frame. A third material supply bridge is then moved over the worktable to apply adhesive on the sheeting in a pattern mirroring the steel frame.

Description

[0001] This application claims the benefit of U.S. Provisional Application No. 60 / 513,222, filed Oct. 23, 2003.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a novel system for constructing modular housing structures. In particular, the modular housing system produces light gauge steel modular structures. The system is capable of producing all types of panels including insulated closed panels having installed electrical and mechanical system. [0004] 2. Description of Related Art [0005] The present inventor, with the benefit of 40 years in the design and construction industry, has developed a modular housing system that will provide stronger homes. The system gives full consideration to national building codes, and the underlying principles of safety, comfort, energy savings, and green construction. The housing system will provide the best retirement plan for America's aging population, a higher quality manufactured home providing...

AI Technical Summary

Benefits of technology

[0019] An object of the present invention is to provide a modular housing system that can satisfy the public's desire for higher pitched roofs, provide historic aesthetics, and convert the industry's present wood trusses, which wasted volumes of costly space, to usable and accessible attic storage and bedrooms.

[0020] The system employs the present inventor's flat shipped, panel roof, which is rolled up into place by a crane while setting the modules at the job site, accomplishes this entire transition. Converting the modular roof system from trusses to closed and open flat panel components simplifies the entire modular structure. This enables true industrialization and mass production of every major flat panel component composing a modular house on one CNC (computer numerical control) encoder driven work table, consuming only 3300 square feet of plant floor area. As demonstrated in FIG. 1, the necessary plant size is significantly less in comparison with the typical wood modular plant. In the present invention, the work table is connected to an overhead tram, which transports the finished panels to the assembly table where all the panel components, which compose the module, are assembled.

[0029] The novel modular housing system can be arranged in two forms, i.e., a standard semi-mechanized manual system which is contemplated to be primarily used in under-developed nations in which the cost of labor is low; and an optional totally mechanized system applicable primarily in developed nations in which the labor costs are relatively high.

Problems solved by technology

The construction of modular building structures, which are fabricated at a housing plant, is limited by applicable laws and regulations.

These limitations include width restrictions to insure vehicular safety, height restrictions to clear overhead obstructions, and length restrictions of the modular unit and transporter.

Typically manufactured HUD homes and modular homes include three dimensional “boxes or modules” that are shipped over the road, and thus are confronted with the continuing problem of the regulatory shipping limitations.

Accordingly, the most economical roof designs have generally been limited to low and medium pitched roofs.

Also, the height limitations impose constraints on the design of the building structures, and the building structures have taken on the connotations associated with the homes produced by the earlier mobile home industry.

However, shipping independent roof sections substantially increases the construction and transportation costs, and saddle roof designs consume a portion of the over-the-road regulatory width, thereby reducing the allocable width of the module living space.

Both of these methods have limitations and increase the cost of equivalent floor area in the building structures.

Furthermore, the applicable laws have created several limitations within the modular housing industry such as:

Also, as the lengths of the modules have been extended upward in excess of 70 feet, the modules have been exposed to increased flexure during shipping and handling, resulting in increased damage to both the structure and interior finishes of the module.

However, this requires the production of additional multiple panels and substantially increases costs.

Furthermore, this process exposes the module to potential weather damage during the erection procedure.

Saw-tooth roof configurations are inconsistent with the aesthetics of traditional home designs.

However, this has been accomplished by increasing the exterior wall area, which inherently increases the heating and cooling costs.

The above-discussed limitations have affected not only the housing product itself, but have also imposed restrictions on the siting of the homes on the lots.

This is necessary to avoid the alternative positioning at 90 degrees to the front lot line, which would place the front entrance adjacent to the side lot line and thereby provide inadequate visibility from the street.

Further, the lengthened modules require wider lots, which inherently increases the infrastructure cost of the lots.

Also, the present lengthened modules are not compatible with the concept of clustered housing on smaller lots, which is being promoted today in order to reduce housing costs.

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