Portable modular factory structure and method of constructing same

Abstract

A method of converting shipping containers containing factory equipment into a modular portable factory which comprises transporting the shipping containers to the factory site and aligning the containers in a side-by-side relation with their facing walls, to define the walls of the factory and floor of the factory. A roof structure spans over the top of the container to form top closure for the factory and access doors and stairways are provided in the factory. Shipping containers (main storage units) containing building materials are mounted on a foundation with the supply containers placed perpendicular, parallel or angled to the main storage units. The supply containers are movable by a supply track and the product moved by an assembly track, respectively, and turntables at the end of each of these tracks are operatively connected to the tracks to move the supplies or products in a desired direction. The invention also provides a novel portable modular factory which can be assembled on one site and readily disassembled for relocation to another site.

1 . A portable modular factory comprising at least two shipping containers containing preassembled factory building components, said shipping containers being removably linked together to form a pair of opposed walls of said factory, a roof structure formed over said shipping containers, a passageway extending between said opposed walls of said factory, at least one access opening in each of said opposed shipping containers for transportation of supply materials to said passageway via said access opening.  
     
     
         2 . A portable modular factory as in  claim 1  further including at least one supply container substantially adjacent at least one of said shipping containers.  
     
     
         3 . A portable modular factory as in  claim 2  further including at least one assembly line track.  
     
     
         4 . A portable modular factory as in  claim 3  further including at least one supply line track for moving the supply container.  
     
     
         5 . A portable modular factory as in  claim 2  wherein a supply container is placed substantially perpendicular to each shipping container.  
     
     
         6 . A portable modular factory as in  claim 2  wherein a supply container is placed substantially parallel to each shipping container.  
     
     
         7 . A portable modular factory as in  claim 2  wherein at least two spaced apart supply containers are placed substantially perpendicular to a shipping container.  
     
     
         8 . A portable modular factory as in  claim 2  wherein at least two spaced apart supply containers are placed substantially adjacent to at least one shipping container.  
     
     
         9 . A portable modular factory as in  claim 4  wherein at least one supply container is placed substantially parallel to each shipping container in supply communication through said access opening to said passageway.  
     
     
         10 . A portable modular factory as in  claim 4  further including a means at the respective ends of each of said tracks operatively associated therewith for causing movement of each track.  
     
     
         11 . A portable modular factory as in  claim 10  wherein each of said means is a turntable.  
     
     
         12 . A portable modular factory as in  claim 2  wherein at least two rows of at least one main storage unit stacked one above the other and wherein a stairway is provided for access from one row to the other.  
     
     
         13 . A portable modular factory as in  claim 3  wherein at least two rows of at least one shipping container each are stacked one above the other and wherein a stairway is provided for access from one row to the other.  
     
     
         14 . A portable modular factory as in  claim 4  wherein at least two rows of at least one shipping container stacked one above the other and wherein a stairway is provided for access from one row to the other.  
     
     
         15 . The method of constructing a portable modular factory from shipping containers containing factory components in said containers, said method comprising: 
 (a) securing at least two shipping containers on a supporting foundation, linking said containers in substantially abutting relation to form walls of said factory,    (b) installing a roof structure over the top of said containers,    (c) installing an access opening in the side walls of at least one of said shipping containers,    (d) installing an assembly track for moving product through said factory.    
     
     
         16 . A method as in  claim 15  wherein each shipping container is located offsite and transporting each container to the factory site.  
     
     
         17 . A method as in  claim 15  wherein means is used for moving said product through said factory.  
     
     
         18 . A method as in  claim 16  wherein means is used for moving said product through said factory.  
     
     
         19 . A method as in  claim 15  wherein at least two rows of shipping containers are stacked each over the other and a stairway is installed for access from a lower row to an upper row.  
     
     
         20 . A method as in  claim 16  wherein at least two rows of shipping containers are stacked each over the other and a stairway is installed for access from a lower row to an upper row.  
     
     
         21 . A method as in  claim 17  wherein at least two rows of shipping containers are stacked each over the other and a stairway is installed for access from a lower row to an upper row.  
     
     
         22 . A method of fabricating modular buildings through the use of a modular factory, comprising the steps of: 
 (a) adapting shipping containers for combination into a modular factory,    (b) further adapting said shipping containers to contain equipment for fabricating modular buildings,    (c) transporting said shipping containers to a factory site,    (d) combining said shipping containers to form a modular factory on said factory site, and    (e) fabricating modular buildings at least in part in said modular factory.    
     
     
         23 . A method of fabricating modular buildings through the use of a modular factory in accordance with  claim 22 , additionally comprising the step of: 
 further adapting said shipping containers for receiving supplies for fabricating modular buildings by means of external openings therein and for delivering said supplies by means of internal openings therein.    
     
     
         24 . A method of fabricating modular buildings through the use of a modular factory in accordance with  claim 23 , additionally comprising the step of: 
 (a) adapting said external openings to receive supply container modules,    (b) locating said internal openings opposite said external openings to permit straight line pass through of supplies from said supply container modules through said shipping containers to the factory floor of said modular factory.    
     
     
         25 . A method of fabricating modular buildings through the use of a modular factory in accordance with  claim 23 , additionally comprising the step of: 
 (a) raising entire factory to conventional truck dock elevation, and    (b) locating standard container and trailer to external openings to supply factory.    
     
     
         26 . A method as in  claim 22  wherein at least two rows of shipping containers are stacked each over the other, and a stairway is installed for access from one row to the other row.  
     
     
         27 . A method as in  claim 23  wherein at least two rows of shipping containers are stacked each over the other, and a stairway is installed for access from one row to the other row.  
     
     
         28 . A method as in  claim 24  wherein at least two rows of shipping containers are stacked each over the other, and a stairway is installed for access from the lower level to the upper level.  
     
     
         29 . A modular building fabricated by the method of  claim 22 .  
     
     
         30 . A modular building fabricated by the method of  claim 23 .  
     
     
         31 . A modular building fabricated by the method of  claim 24 .  
     
     
         32 . A modular building fabricated by the method of  claim 25 .  
     
     
         33 . A system for fabricating products on a temporary site through the use of a portable factory, comprising the steps of: 
 (a) selecting a site,    (b) preparing said site to receive a portable factory,    (c) assembling a plurality of first shipping containers to form a portable factory on said site, and    (d) fabricating products by means of said portable factory.    
     
     
         34 . A system for fabricating products on a temporary site through the use of a portable factory in accordance with  claim 33 , additionally comprising the steps of: 
 (a) docking supply shipping containers to at least one opening provided in an external wall of at least one of said first shipping containers of said portable factory, and    (b) delivering supplies to said portable factory by means of said supply shipping containers.    
     
     
         35 . A system for fabricating products on a temporary site through the use of a portable factory in accordance with  claim 33 , additionally comprising the steps of: 
 (a) disassembling said portable factory, and    (b) removing at least one of said first shipping containers from said site.    
     
     
         36 . A building fabricated by the system of  claim 33 .  
     
     
         37 . A building fabricated by the system of  claim 34 .  
     
     
         38 . A building fabricated by the system of  claim 35 .  
     
     
         39 . A system as in  claim 33  wherein said product is a building.  
     
     
         40 . A system as in  claim 34  wherein said product is a building.  
     
     
         41 . A system as in  claim 35  wherein said product is a building.