Prefabricated Building Components and Assembly Equipment

Abstract

A building process that offers better qualities in terms of value, structural integrity, and comfort and energy conservation for industrial, commercial and residential building industries. The present invention starts with a single component which is the vertical composite insulated supporting steel member, then the plate, the beam, the floor joist, the roof truss members and the multiple insulation patterns to create the cavities. The entire concept of utilizing the invention is that the design of all of the components and parts, the objectives are focused on to facilitate the prefabrication process and conserve energy.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention relates generally to building material and, more specifically, to a building process that offers better qualities in terms of value, structural integrity, and comfort and energy conservation for industrial, commercial and residential building industries. The present invention starts with a single component which is the vertical composite supporting steel member (stud), then the plate, the beam, the joist, the roof truss system and the multiple insulation patterns to create the cavities. The entire concept of utilizing the invention is that the design of all of the components and parts, the objective is focused on one, which is to facilitate the prefabrication process.[0003]2. Description of the Prior Art[0004]There are other building components designed for the same purpose. Typical of these is U.S. Pat. No. 3,161,267 issued to Keller on Dec. 15, 1964.[0005]Another patent was issued to Burges on No...

AI Technical Summary

Benefits of technology

[0025]A unique wall panel is constructed from expanded polystyrene beads in an expanded polystyrene mold with structural members embedded in it during the molding process. The structural members are in the form of two by four studs placed at sixteen inch centers. Adjacent panels have interlocking grooves and ridges which fit together. The advantage of the present invention is that a total insulated wall is created with no cracks or spaces in the insulation. These lightweight panels can be carried to the building site, where base and top plates are applied and the panels interlocked to form a perfectly insulated wall.

[0026]A composite building panel includes a core of a foamed polymeric insulating material, such as expanded polystyrene, having a plurality of uniformly spaced open box tubes retained in vertical grooves formed in the rear surface of the core by a two-part epoxy adhesive, the tubes being mechanically connected at their ends to one leg of continuous horizontal channels having their other leg adhesively secured to the core at horizontal slots. The front surface of the core is continuous without seams and may be coated with a variety of exterior insulation finishing system coatings.U.S. Pat. No. 5,269,109Inventor: V. Rao GularIssued: Dec. 14, 1993

[0027]An insulated load bearing wall (10, 10′) comprising panels of extruded polymer foam (20, 22, 50, 52, 54, 56) into which tubular, load carrying frame members (12, 14, 48) have been incorporated. A tongue is formed at one vertical edge of each panel (10, 10′) and a groove is formed at the opposite vertical edge. The tubular frame members (12, 14, 48) are bonded to the extruded polymer foam.U.S. Pat. No. 5,765,330Inventor: Michel V. RichardIssued: Jun. 16, 1998

[0028]A pre-insulated prefab wall panel comprising of a rectangular wall frame having top and bottom rail members and a plurality of spaced apart stud members aligned between the top and bottom rail members. A polystyrene boardstock is affixed to a first side of the rectangular wall frame, thereby defining with the top and bottom rail members and the plurality of stud members a plurality of rectangular cavities, wherein each cavity has a depth of the thickness of a stud member. The prefab wall panel further has a layer of foamed-in-place polyurethane covering a portion of each cavity adjoining the boardstock, and bonding the structural wall frame to the polystyrene boardstock. The layer of polyurethane foam has a thickness which is substantially less than the depth of each cavity, whereby each cavity has available space for accommodating sub-trade installations.U.S. Pat. No. 5,953,883Inventor: Leo V. OjalaIssued: Sep. 21, 1999

[0029]An insulated wall panel comprising a bottom, a plurality of inner members, a plurality of outer members, spacers between the inner members and the outer members, an insulation layer, an exterior sheathing, a vapor barrier, a top member and a planar interior wall. The insulated wall panel has a dead air space located just inside of a cavity filled with insulation. The wall panel is adapted to be secured to the frame of a timber frame home without fasteners passing through the entire depth of the panel. Fasteners secure the inner members of the panel only to the frame without destroying the integrity of the insulated wall panel.U.S. Pat. No. 6,158,190Inventor: Stephen SengIssued: Dec. 12, 2000

[0030]This composite building stud combines two metal shapes, inner and outer, with an insulating material to form a composite structural member having an insulating valve (R-value) greater than a similar metal member normally used as a stud in a residential structure. The composite also has a strength comparable to that of a similar steel member normally used as a stud in a residential structure. One shape encompasses the other shape. The composite structural member eliminates any direct metal connections and thus eliminates any thermal shorts that reduce the overall insulating value (R-value) of the composite member. The shapes, inner and outer, with an insulating material form a composite structural member that has an interlocking shape which holds the insulating material in compression and mechanically couples the inner and outer members.U.S. Pat. No. 6,857,237Inventor: Raymond F. Dalphond, et al.Issued: Feb. 22, 2005

Problems solved by technology

Such joints permit detrimental heat transfer through the insulation.

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