Abstract:
A manufacturing platform has one or more tables for producing construction components such as walls, floors, decks and roofs. The tables are pivotally mounted on second and/or third axes at the outboard edges or rear end of a pair of rectangular horizontal frames which are pivotally mounted on first axes on either side of a trailer. Actuating means tilts each table outward about the second axis or rearward about the third axis to an upright position for removal of the finished construction components, and tilts each table and corresponding frame together inward about the first axis to an upright storage position for trailer transport. Locking means secures and releases the tables to the frames. A first axis support is either the trailer or a foundation affixed to a floor. A second support at the outboard edge of the frame is selectively variable in height to level the table.

Description:
[0001]    The present invention relates generally to construction equipment and pertains, more specifically, to a construction component manufacturing platform upon which custom or standard parts can be produced for a building or structure. The invention can be configured as a stationary or mobile platform equipped with a plurality of manufacturing tables, each fitted with a lifting mechanism and optional vibrators and heaters.  
           [0002]    Heretofore, construction components have been fabricated on site in a variety of ways. Wood components are assembled one piece at a time either in their finished position, or on the uneven ground, or on a construction site cluttered with debris. This is laborious, and sometimes even dangerous. Every component is custom made, even if multiple dwellings are to be built identically. Concrete components are made by erecting molds in place and pouring concrete into the molds. Each mold is essentially custom made for the job, and is disassembled afterward. The process is labor intensive and inefficient. Previous construction techniques have not been able to overcome these problems, as shown in the following U.S. patents:  
           [0003]    Solomon, U.S. Pat. No. 5,524,861, shows a system of panels forming a mold for casting an entire outer wall of a building in one piece; Del Monte, U.S. Pat. No. 5,520,531, discloses a portable, heated mold for forming concrete wall segments; Sasaki, U.S. Pat. No. 5,616,349, reveals a mold, variable in height, for forming a horizontal concrete slab; and Lee, U.S. Pat. Nos. 5,329,742, and 5,490,367, depict an apparatus for supporting and moving vertically a mold for forming the walls of a building.  
           [0004]    While the prior art devices are functional in the construction of concrete walls or slabs, none of them are versatile enough to be used with either concrete, wood, or metal construction. Nor can any be used to form outside or inside walls that are completely finished on both sides, including studs, liners, plates, corners, sheathing, and lintels over windows and doors. Nor can they provide for walls complete with fiberglass or foam insulation, piping, electrical wiring and outlets, and paneling or drywall ready for decorative finish. None can be used to fabricate floor panels, decks, and roof panels. They cannot be utilized to form walls of brick, stone, stucco, or block, with different aggregates in the same wall.  
         SUMMARY OF THE INVENTION  
         [0005]    The present invention provides a platform for the manufacture of finished construction components made from any material. The platform can be fixed to a foundation in a plant, and used in a stationary mode. In this manner, it can be utilized to produce all kinds of products including building and structural components.  
           [0006]    The platform can just as well be mounted on a trailer and towed with a truck tractor to a construction site with the platform table or tables in the raised, storage position, facing inward on the trailer. At the site, the table or tables are lowered into the horizontal, operative position and leveled. There, concrete forms are set up on the platform table, the forms being made from steel, aluminum, wood, plastic, or other like rigid materials. Outside surface materials, for example brick, are placed on the flat table surface, thus defining the outside wall surface. Reinforcing bars are placed in the forms, along with electrical conduit, plumbing, lintels over openings, and other structural elements. After pouring concrete, insulation and interior surfaces are installed. When the concrete is set, the locking means is released, and the platform table is raised into the discharge position facing outward on the trailer. The wall component, now erect, is then lifted from the platform and set into place in the building. In the case of wood construction, fixtures may be attached to the table surface to position various components. Outside sheathing is placed on the table surface, then the plate, studs, headers, liners, etc., are added. Windows and doors can be installed at this point. Electrical conduits and outlets are added next, along with plumbing, then insulation. Interior paneling or sheetrock is installed last. The table is then raised as before, and the wall is removed. In a similar manner, roof panels, floors, decks, stairs, railings, and architectural embellishments can be quickly, safely, and efficiently produced.  
           [0007]    The above features, as well as further features and advantages, are attained by the present invention which may be described briefly as a manufacturing platform comprising a table having upper and lower surfaces extending between opposite first and second edges and opposite front and rear ends. A frame extends between opposite first and second edges. The frame second edge and rear edge pivotally attaches to the table adjacent the table second edge or at the rear edge between the first and second edges for supporting the table and allowing the table to pivot about a second axis or a third axis. Locking means are included for selectively locking the table to the frame to prevent pivotal movement of the table about the second axis or third axis, and releasing the table from the frame to allow pivotal movement of the table about the second axis or third axis.  
           [0008]    A first support is pivotally attached to the frame adjacent the frame first edge for supporting the frame and allowing the frame to pivot about a first axis. A second support and third support is each attached to the frame adjacent the frame&#39;s respective second edge and rear end for supporting the frame.  
           [0009]    Actuating means is further included for selectively actuating the table and frame together about the first axis to an upright storage position over the first support and to a substantially horizontal operative position wherein the table is used to manufacture the construction component with the locking means locked.  
           [0010]    The actuating means also serves for selectively actuating the table about the second axis or third axis to an upright discharge position for removal of the construction component from the table as well as to the substantially horizontal operative position, at which the table is closely juxtaposed and substantially parallel with the frame with the locking means released. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    The invention will be more fully understood, while still further features and advantages will become apparent, in the following detailed description of preferred embodiments thereof illustrated in the accompanying drawings, in which:  
         [0012]    [0012]FIG. 1 is a perspective view of a manufacturing platform constructed in accordance with the invention;  
         [0013]    [0013]FIG. 2 is another perspective view of the manufacturing platform of FIG. 1;  
         [0014]    [0014]FIG. 3 is a plan view of the manufacturing platform of FIG. 1;  
         [0015]    [0015]FIG. 4 is a rear elevation view of the manufacturing platform of FIG. 1;  
         [0016]    [0016]FIG. 5 is a rear elevation view of the manufacturing platform of FIG. 1, showing another aspect of the invention;  
         [0017]    [0017]FIG. 6 is a rear elevation view of the manufacturing platform of FIG. 1, showing a further aspect of the invention;  
         [0018]    [0018]FIG. 7 is a rear elevation view of another manufacturing platform constructed in accordance with the invention;  
         [0019]    [0019]FIG. 8 is a rear elevation view of the manufacturing platform of FIG. 7, showing another aspect of the invention;  
         [0020]    [0020]FIG. 9 is a rear elevation view of the manufacturing platform of FIG. 7, showing a further aspect of the invention;  
         [0021]    [0021]FIG. 10 is a localized perspective view of the table portion of the platform showing the invention in use; and  
         [0022]    [0022]FIG. 11 is a localized perspective view of the table portion of the platform showing another use of the invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]    Referring now to the drawing, and especially to FIGS. 1, 2,  3 ,  4 ,  5 , and  6 , a manufacturing platform is shown at  20 , and includes one or more tables, single or in pairs, made of steel or aluminum plate. When constructed as one or more pairs, each pair typically includes a right table  22  and a left table  24 . Each table has upper and lower surfaces, including a right upper surface  26  and a right lower surface  28 , and a left upper surface  30  and a left lower surface  32 . The surfaces extend between opposite first and second edges, including a right first edge  34  and a right second edge  36 , and a left first edge  38  and a left second edge  40 , respectively. The surfaces also extend between opposite front and rear ends, including a right front end  42  and a right rear end  44 , and a left front end  46  and a left rear end  48 , respectively. The right table  22  and the left table  24  each includes a plurality of reinforcing members  50  adjacent the lower surfaces  28  and  32 , respectively, to limit deflection of the table surfaces.  
         [0024]    The platform further comprises a pair of frames, including a right frame  52  and a left frame  72 , for supporting the right table  22  and the left table  24 , respectively. Each frame is constructed from four structural members welded together at the comers, forming a rectangle.  
         [0025]    The right frame  52  includes a right first edge member  54  extending between opposite front  56  and rear  58  ends, and a right second edge member  60  extending between opposite front  62  and rear  64  ends. The first edge member  54  is spaced apart from and substantially parallel to the second edge member  60 . A right front member  66  extends between the first edge member front end  56  and the second edge member front end  62 . A right rear member and third axis  68  extends between the first edge member rear end  58  and the second edge member rear end  64 . The front member  66  is substantially parallel to the rear member  68 . The right frame  52 , adjacent the right frame second edge member front end  62  and rear end  64  and the third axis  68  between first edge  58  and second edge  64  and adjacent to the right table rear edge  44 , is pivotally attached to the right table  22  adjacent the right table second edge  36  and rear end  44 . This pivotal attachment supports the right table  22  in a position closely juxtaposed and substantially parallel with the right frame  52  and allows the right table  22  to pivot about a right second axis  70  or right third axis  68  between first edge  58  and second edge  64  parallel with the rear end of Table  44 . The invention incorporates the combination of the second and third axis allowing the table to be pivoted at the axis most suitable for any given construction component.  
         [0026]    The left frame  72  includes a left first edge member  74  extending between opposite front  76  and rear  78  ends, and a left second edge member  80  extending between opposite front  82  and rear  84  ends. The first edge member  74  is spaced apart from and substantially parallel to the second edge member  80 . A left front member  86  extends between the first edge member front end  76  and the second edge member front end  82 . A left rear member  88  extends between the first edge member rear end  78  and the second edge member rear end  84 .  
         [0027]    The front member  86  is substantially parallel to the rear member  88 . The left frame  72 , adjacent the left frame second edge member front end  82  and rear end  84 , is pivotally attached to the left table  24  adjacent the left table second edge  40  and the third axis  88 , between the first edge  78  and second edge  84  and adjacent to the left table rear end  48 , for supporting the left table  24  and allowing the left table  24  to pivot about a left second axis  90  or left third axis  88  for supporting the left table  24  and allowing the left table  24  to pivot about a left second axis  90  or left third axis  88 . The left frame  72 , adjacent the left frame second edge member front end  82  and rear end  84 , is pivotally attached to the left table  24  adjacent the left table second edge  40 . This pivotal attachment supports the left table  24  in a position closely juxtaposed and substantially parallel with the left frame  72  and allows left table  24  to pivot about a left second axis  90  and rear third axis  88 .  
         [0028]    Locking means is provided for selectively locking each table to the respective frame, to prevent pivotal movement of each table about the respective second or third axis, and for releasing each table from the respective frame to allow pivotal movement of each table about the respective second axis or third axis.  
         [0029]    At least two table locking members  92 , are attached to each table  22  and  24 , and serve as table locking means. The table locking members  92 , typically will be a pair of reinforcing members disposed transversely under each table. Each table locking member  92  has a hole  94  there through adjacent the table first edges  34  and  38  and substantially parallel to the table surfaces  26  and  30 . A plurality of frame locking members  96  are provided, typically mounted in pairs to each frame front member  66  and  86 , and to each frame rear member  68  and  88 , adjacent each frame first edge member  54  and  74  respectively, and projecting outward or rearward toward the corresponding table  22  and  24 . Each pair of frame locking members  96  is disposed on either side of one of the table locking members  92 , and each frame locking member  96  has a hole  98  therethrough in alignment with the respective table locking member hole  94  when the table is in a position closely juxtaposed and substantially parallel with the respective frame. A plurality of locking pins  100  are provided, including one locking pin  100  engaging each table locking member hole  94  and the corresponding frame locking member hole  98 .  
         [0030]    A pair of right first supports are provided to support the weight of the table, frame, and construction component near the inboard or first edge of the right table. Included are a front right first support  102  pivotally attached to the right frame  52  adjacent the connection of the first edge member  54  to the front member  66 , and a rear right first support  104  pivotally attached to the right frame  52  adjacent the connection of the first edge member  54  to the rear member  68 , for supporting the right frame  52  and allowing the right frame to pivot about a right first axis  106 . Also provided are a pair of left first supports, to support the weight of the table, frame, and construction component near the inboard or first edge of the left table. Included are a front left first support  108  pivotally attached to the left frame  72  adjacent the connection of the first edge member  74  to the front member  86 , and a rear left first support  110  pivotally attached to the left frame  72  adjacent the connection of the first edge member  74  to the rear member  88 , for supporting the left frame  72  and allowing the left frame to pivot about a left first axis  112 .  
         [0031]    A pair of right second supports  114 , being selectively variable in height, are used to support the weight of the table, frame, and construction component near the outboard or second edge  36  of the right table  22 . One support  114  is attached to the right frame  52  adjacent the connection of the second edge member  60  to the front member  66 , and one support  114  is attached to the right frame  52  adjacent the connection of the second edge member  60  to the rear member  68 , for supporting the right frame  52 . A pair of left second supports  116 , being selectively variable in height, are used to support the weight of the table, frame, and construction component near the outboard or second edge  40  of the left table  24 . One support  116  is attached to the left frame  72  adjacent the connection of the second edge member  80  to the front member  86 , and one support  116  is attached to the left frame  72  adjacent the connection of the second edge member  80  to the rear member  88 , for supporting the left frame  72 .  
         [0032]    The supports can take any number of forms, including scissor jacks, screw jacks, hydraulic cylinders, etc., or telescoping tubes as described next.  
         [0033]    Each support of the pair of right  114  and left  116  second supports includes a first tubular member  113  having at least one transverse hole. A second tubular member  115  slideably engages the first tubular member  113 . The second tubular member  115  has a plurality of transverse holes spaced apart longitudinally. A support pin  117  selectively engages one of the holes in each of the first  113  and second  115  tubular members, in order to adjust the table to a level operating position.  
         [0034]    The platform includes a front right linear actuator  134 , and a rear right linear actuator  140 , which serve as right actuating means for selectively actuating or lifting the right table  22  and right frame  52  together in an arcing motion about the right first axis  106  to an upright storage position over the right first supports  102  and  104 , as shown by arrow  118  in FIG. 4. The table must be secured to the frame with the locking means locked. In the storage position, the tables and frames can be transported over the road to the job site. The right actuating means also actuates or lowers the right table  22  and right frame  52  together from the storage position to a substantially horizontal operative position, as shown by arrow  122  in FIG. 5. Again, the locking means must be locked. In the operative position, the right table  22  will be used to manufacture the construction component, as described above. The same right actuating means is used for selectively actuating or lifting the right table  22  about the right second axis  70 , to an upright discharge position over the right second supports  114 , as shown by arrow  126  in FIG. 6. With the locking means released, as it now must be, the actuating means is no longer compelled to lift the combined weight of the table and frame, but only that of the table, which is semi-balanced. Thus, the frame remains on the ground and the table rises, this time in the other direction. In the discharge position, the construction component will be removed from the right table. The right actuating means also actuates or lowers the right table  22  to the substantially horizontal operative position as shown by arrow  130  in FIG. 5. The locking means remains released as the right table  22  is lowered back into the operative position closely juxtaposed and substantially parallel with the right frame  52 .  
         [0035]    The platform also includes a front left linear actuator  146 , and a rear left linear actuator  152 , which serve as left actuating means for selectively actuating or lifting the left table  24  and left frame  72  together in an arcing motion about the left first axis  112  to an upright storage position over the left first supports  108  and  110 , as shown by arrow  120  in FIG. 4. The table must be secured to the frame with the locking means locked. The left actuating means also actuates or lowers the left table  24  and left frame  72  together from the storage position to a substantially horizontal operative position, as shown by arrow  124  in FIG. 5. Again, the locking means must be locked. In the operative position, the left table  24  will be used to manufacture the construction component, as described above. The same left actuating means is used for selectively actuating or lifting the left table  24  about the left second axis  90 , to an upright discharge position over the left second supports  116 , as shown by arrow  128  in FIG. 6. The locking means is now released. With the table now in the discharge position, the construction component will be removed from the left table. The left actuating means also actuates or lowers the left table  24  to the substantially horizontal operative position as shown by arrow  132  in FIG. 5. The locking means remains released as the left table  24  is lowered back into the operative position closely juxtaposed and substantially parallel with the left frame  72 .  
         [0036]    The linear actuators typically will be either hydraulic cylinders or electric motor driven screw type actuators, although other type actuators can be utilized.  
         [0037]    The front right linear actuator  134  has opposite first  136  and second  138  ends, and the rear right linear actuator  140 , has opposite first  142  and second  144  ends. The front right linear actuator first end  136  is pivotally attached to the front right first support  102  below the right first axis  106 . The front right linear actuator second end  138  is pivotally attached to the right table  22  intermediate the first  34  and second  36  edges. The rear right linear actuator first end  142  is pivotally attached to the rear right first support  104  below the right first axis  106 . The rear right linear actuator second end  144  is pivotally attached to the right table  22  intermediate the first  34  and second  36  edges.  
         [0038]    The front left linear actuator  146  has opposite first  148  and second  150  ends, and the rear left linear actuator  152 , has opposite first  154  and second  156  ends. The front left linear actuator first end  148  is pivotally attached to the front left first support  108  below the left first axis  112 . The front left linear actuator second end  150  is pivotally attached to the left table  24  intermediate the first  38  and second  40  edges. The rear left linear actuator first end  154  is pivotally attached to the rear left first support  110  below the left first axis  112 . The rear left linear actuator second end  156  is pivotally attached to the left table  24  intermediate the first  38  and second  40  edges.  
         [0039]    The mobile version of the manufacturing platform includes a trailer, which serves as the pair of right first supports and the pair of left first supports. The trailer  158  comprises a chassis  160  extending longitudinally between opposite front  162  and rear  164  ends, the chassis having two longitudinal girders, including a right girder  166  and a left girder  168 . Two beams are attached to the girders transversely, including a front beam  170  extending between the girders and projecting outward from the right girder  166  to a right front beam end  172 , and projecting outward from the left girder  168  to a left front beam end  174 . Also included is a rear beam  176  extending between the girders and projecting outward from the right girder  166  to a right rear beam end  178 , and projecting outward from the left girder  168  to a left rear beam end  180 , with the right front  172  and right rear  178  beam ends pivotally engaging the right frame  52  on the right first axis  106 , and the left front  174  and left rear  180  beam ends pivotally engaging the left frame  72  on the left first axis  112 . The trailer  158  includes an axle with wheels and tires  182 , mounted to the chassis  160  adjacent the chassis rear end  164 . Also included is a hitch  184  mounted on the chassis front end  162 .  
         [0040]    An optional feature of the platform is a plurality of vibrators  186  attached to the lower surfaces of each table to aid the concrete in flowing into recesses in the mold, and to consolidate concrete by eliminating air pockets.  
         [0041]    Another optional feature of the platform is a plurality of heaters  188  attached to the lower surfaces of each table for reducing concrete curing time.  
         [0042]    Turning now to FIGS. 7, 8, and  9 , another manufacturing platform constructed in accordance with the invention is shown at  190 . This platform is stationary and differs from the mobile platform described above only in details of the first supports. Therefore, the same part numbers and accompanying descriptions will be used as for the right-hand portions of the mobile platform.  
         [0043]    A pair of stationary first supports  192  are provided to support the weight of the table, frame, and construction component near the inboard or first edge of the right table. Included are a stationary first support  192  pivotally attached to the frame  52  adjacent the connection of the first edge member  54  to the front member  66 , and a stationary first support  192  pivotally attached to the frame  52  adjacent the connection of the first edge member  54  to the rear member  68 , for supporting the frame  52  and allowing the frame to pivot about a first axis  106 .  
         [0044]    The stationary first supports  192  are typically affixed to the floor  194  of a manufacturing facility for permanent production work.  
         [0045]    Referring now to FIG. 10, the table  22  of a mobile  20  or stationary  190  manufacturing platform as described above is shown being used for casting a concrete construction component. A mold  196  is assembled on the upper surface  26  of the table  22 . Reinforcing bars  198  are installed in the mold prior to pouring concrete.  
         [0046]    Turning now to FIG. 11, the table  22  is shown being used to build a wood frame wall. Illustrated are the plate  200 , studs  202 , liners  204 , door header  206 , window header  208 , and sole  210 , which comprise the principal structural members.  
         [0047]    It is to be understood that the above detailed description of embodiments of the invention is provided by way of example only. Various details of design and construction may be modified without departing from the true spirit and scope of the invention as set forth in the appended claims.