Method of manufacturing housing module gable

Abstract

An edge beam construction including two vertical perforated rolled shapes with webs inverted toward the center of the beam, and a bottom track having a flange disposed in a vertical position against bottom lips of the vertical rolled shapes. The three basic components of the edge beam are positioned so as to provide access for press joining tools. A building module manufacturing method utilizes the light gauge steel rolled shapes that permit industrialized, automated manufacture of floor, roof and wall panels for modular housing and commercial structures with integrated mechanical and electrical systems and rigid framing for road transport without trailers. The module manufacturing method includes a novel method of constructing and positioning a gable.

Description

[0001]This is a divisional application of Ser. No. 11 / 516,661, filed Sep. 7, 2006, which claims the benefit of U.S. Provisional Application No. 60 / 714,371, filed Sep. 7, 2005, the entire contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates to a novel method of industrial, automated manufacture of light gage steel floor, roof and wall panels, with exceptional energy properties, to form stronger building modules of varying width, height and length. The invention provides structures of one to four stories for homes, offices, motels, hotels and other cellular structures. The method also allows aesthetic flexibility for a wide range of products, from traditional family home designs to contemporary structures including large glass surfaced areas and spatial elements. The invention uses lighter weight materials; thereby reducing module weight by approximately 40% of modules produced by the curre...

AI Technical Summary

Benefits of technology

[0013]Perforated rolled shapes used in both the transverse and longitudinal direction of the floor, ceiling, and roof panels, and the vertical exterior and marriage walls of the modules perform the multi-function of energy conservation and distribution of mechanical, plumbing, and electrical access to transfer services within and between the modules composing the structure. The invention reduces thermal conductance by employing standard multi-perforated open web rolled shapes manufactured by several companies to minimize energy transfer to and from the outside through the structural system. Also, the perforated rolled shapes offer connection points for transport assemblies, thereby eliminating the need for costly transport trailers.

Problems solved by technology

However, the current modular industry has not yet achieved full integration of mechanical and utility services as part of an automated production system and is still reliant upon labor intensive technology, historic materials and outdated modes of structural framing.

In addition to requiring weeks to finish a typical 2,000 ft2 house, the industry wastes time and money with outmoded transport methods.

The second method requires expensive, heavy steel framed multi-axle transport trailers to limit damage to gypsum and other relatively soft interior finishes due to module flexion during transport.

Currently the industry standard is far from the ideal product of a complete module including integrated mechanical and utility services, full insulation and efficient use of materials.

Although certain modular industry products approximate the ideal, the mainstream modular industry has developed without the structural, cost and aesthetic advantage of galvanized light gage steel rolled shapes and automated production technologies.

Despite the potential, light gauge steel has not historically been economical primarily due to difficult connection problems.

The attachment of light gauge steel shapes to construct panels for modular structures, limited by national codes and conventions that adhere to historic structural configurations and fastening details, fails to take advantage of the inherent strength of light gauge steel materials.

The galvanized surface that protects steel from rust and corrosion limits the use of welding attachment due to the toxic gas emitted during the welding process.

The use of screw and nailing attachment of the members used to construct onsite structures is labor intensive and does not lend itself to either the multiple directions required of application tools in fastening multiple members or the creation of complex composite structural configurations needed to develop the strength capabilities of light gauge steel rolled shape members.

However, the press joining tools, which can provide fastening of light gage galvanized steel sheets, are bulky and do not lend themselves to multi flexible positioning required for complex designs and difficult to reach members of complex composite designs.

The historic structural configurations preferred and included in today's codes are based on labor intensive materials and hand held tools, which do not lend themselves to automation and the use of press joining fastening.

Limited by current technology, the modular industry has not advanced beyond outdated models and modes of production.

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