Prefabricated building with self-aligning sections and method of manufacture and assembly of same

Abstract

A method for manufacture and assembly of a structure includes manufacturing, at a first location, wall sections and floor / ceiling sections. The sections include structural portions and optionally external and interior finish features. The sections have self-aligning features, which may include rotatable attachments. At least some of the sections are attached to one another with rotatable attachments to define a structure segment. The structure segment may be placed in an assembled position, with the rotatable attachments fixed, and additional finish features are removably applied. The additional finish features are removed, and the structure segment is removed from the assembled position to a compact orientation for shipping. The structure segment may be placed in a shipping container for transport. The structure segment is transported in the folded position to a second location. The structure segment is moved to a final assembly position at the second location. The structure segment is placed on a foundation, removed from its compact orientation to an assembled orientation, and fixed in place. Finish features may be added. Additional structure segments may be placed on the foundation to complete a structure.

Description

FIELD OF THE INVENTION [0001] This invention is in the field of buildings, and in particular in the field of buildings that are partially prefabricated. BACKGROUND [0002] The construction of structures is labor-intensive and expensive. Residential homes, for example, are typically constructed entirely on their foundations. Wooden and steel frames, interior walls, exterior walls, roofs and other elements are typically all assembled from component lumber, drywall and other items, at the construction site. A wide variety of inputs, including specific materials, and specific construction skills, must be combined at the site. Particularly in the aftermath of natural disasters, such as hurricanes, tornadoes, or fires, both materials and supplies, and skilled labor, are often unavailable in the region around the construction site. The process at the site is necessarily time-consuming. As a result of the length of time to complete construction, financing costs on the property at the constru...

AI Technical Summary

Benefits of technology

"The invention is a method of making and assembling a structure by using sections that have supports and can align or rotate. These sections can be temporarily fixed and checked for quality control before being moved to a new position. The structure can then be assembled and finished with interior and exterior features. The technical effect of this method is that it allows for easier and more precise assembly of structures, with better quality control."

Problems solved by technology

The construction of structures is labor-intensive and expensive.

Particularly in the aftermath of natural disasters, such as hurricanes, tornadoes, or fires, both materials and supplies, and skilled labor, are often unavailable in the region around the construction site.

The process at the site is necessarily time-consuming.

As a result of the length of time to complete construction, financing costs on the property at the construction site are increased.

However, the transportation of large components, such as assembled walls, by road, results in oversized loads, which increase transportation costs substantially.

In view of the transportation costs, it has generally been acknowledged that assembly of large components more than about 300 miles from the construction site is not economical.

This limited range also makes it more difficult to employ factory assembly as a partial solution to local shortages of materials and skilled labor.

The limited range of transportation of large components renders impractical taking advantage of considerable variations in wages between relatively distant regions.

Transportation of large components by road also exposes structures to stresses not conventionally encountered by buildings.

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