Method and system for constructing pre-fabricated building

Abstract

The present invention is a method and system for constructing pre-fabricated buildings. Wall panels are provided wherein each wall panel has a plurality of vertically disposed channel-shaped metal studs equidistantly disposed between a bottom plate and top plate. A substantially rigid foam insert is between each of the channel-shaped metal studs of a wall panel to provide insulation and structural support to the wall panel. The foam inserts each have an aperture forming a conduit vertically disposed within the foam insert. An interior spline is inserted between adjacent wall panels and provides the mechanical connection to secure the wall panels together. The interior spline comprises rigid foam with a pair of steel facing adhered on opposing faces of the spline.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 60 / 754,110 filed Dec. 27, 2005. The disclosure of the provisional application is incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates generally to building construction, and more specifically to a method and system for efficiently and economically constructing pre-fabricated residential and commercial buildings. [0004] 2. Description of the Prior Art [0005] Construction costs and quality of manufacture are major problems in the building trades. Many building systems have been proposed and used by others to cut costs and improve quality. Those prior art systems usually have some form of panelized pre-fabricated wall segment design. Many of such systems are in use worldwide. The shortcomings of the prior art pre-fabricated structures include, but are not limited to, inadequacies in the conne...

AI Technical Summary

Benefits of technology

[0017] The present invention was developed to provide structural insulated wall panels that have cement-like facings, are lightweight, pre-insulated, and easily erected by specially trained labor. An important advantage of the present invention using labor with composite classification assembly skills for electric, plumbing, heating and air conditioning is that a single crew can quickly perform all trade requirements.

Problems solved by technology

Construction costs and quality of manufacture are major problems in the building trades.

The shortcomings of the prior art pre-fabricated structures include, but are not limited to, inadequacies in the connection between the pre-fabricated panels, inefficient HVAC systems, and susceptibility to failure under high wind loads.

A shortcoming of this type of complete wall system is that it is cumbersome and does not possess the necessary commonality of use required for mass production.

Further, often times there are problems associated with connecting these wall segments that results from variations in dimensional characteristics and leads to uneven gaps between the wall segments.

Therefore, when typical connectors of the system are steel studs that fit within the panel track framework between wall segments, the web of the studs is incapable of being compressed, as would be needed if the gap spacing were too small, and similarly could not be extended automatically if the gap was oversized.

Another shortcoming of the prior art is the lack of sufficient strength of the connection between wall segments.

However, the stress on the screws connecting the wall segments together is not ideal in that scenario.

However, a short-coming of the tip up panels is that they are so heavy that heavy equipment is needed for panel erection.

Thereby making them unattractive to the residential market.

Another shortcoming of the prior art pre-fabricated building systems is that the HVAC systems are inefficient.

If the door is closed, the room becomes “stuffy”.

Further, it is not practical to provide each room with its own large return duct in addition to the two small diameter inlet ducts.

This would also lead to an increase in air contaminants.

Another shortcoming of the prior art and conventional building methods is the susceptibility to failure from high wind loads.

For example, recent hurricanes caused major structural damage to homes from inadequate retention of roof structures to walls.

The level of protection has improved thereby but is still inadequate for winds in excess of 150 mph.

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