Component panel manufacturing jig

Abstract

Disclosed embodiments include a system for constructing a panel for component construction of an enclosed structure. For example, the system may include a jig having a base and a frame coupled to the base, and an insert configured to position components of the panel within the frame. The frame may be configured to removably retain the insert. The insert can be configured for construction of one of the following types of panels: an exterior wall panel, an interior wall panel, a roof panel, or a flooring panel. For example, the insert may include a plurality of stops configured for positioning of the components of the panel type. In some embodiments, the frame can be rotatably coupled to the base. For example, the frame may be configured for either horizontal rotation or vertical rotation. Methods for constructing panels using jig embodiments are also described herein.

Description

COMPONENT PANEL MANUFACTURING JIGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Application No. 63 / 655,733 filed on June 4, 2024 and entitled, “COMPONENT PANEL MANUFACTURING JIG,” which is incorporated herein by reference in its entirety.BACKGROUND

[0002] Various structures can be used to provide an accommodation. The structures are typically purpose built using raw materials including steel, lumber, siding, and connectors. Each structure can be unique due to the extensive effort needed to construct the structure. Even when building kits are available, the kits typically contain the appropriate amount of raw materials that can then be assembled into a building structure using traditional construction techniques. Once constructed, the structure is essentially permanent and cannot be disassembled such that the structure could be rebuilt or constructed elsewhere and retain its structural stability.

[0003] Alternatively, modular structures can offer the benefit of delivering a premanufactured structure that is merely delivered to the construction location (e.g. for assembly). Modular homes can be convenient when full construction at location may be difficult or resources are scarce. How ever, they ty pically are expensive and difficult to deliver. Traditional pier and beam structures may be delivered in components, such as bricks, pipes, trusses, wood, metal, etc. These components may then be constructed and assembled to create a structure. These traditional structures typically require many specialties to assemble properly, require several governmental certifications, and / or may take longer to construct.

[0004] As such, there is a need for improved methods, systems, and apparatuses for building a structure, for example at the construction location, more efficiently, more easily, and / or more affordably.SUMMARY

[0005] In some embodiments, a system for constructing a panel for component construction can comprise: a jig having a base and a frame coupled to the base; and an insert configured to position components of the panel within the frame. The frame can be configured to removably retain the insert. In some embodiments, the frame may be rotatably coupled to the base.

[0006] In some embodiments, a method for constructing a panel for a building system can comprise: providing a jig having a frame rotatably coupled to a base; removably installing an insert within the frame of the jig, wherein the insert is configured to position components of the panel within the frame; positioning components of a first side of the panel within the frame using theinsert; assembling the components to form the first side of the panel; (optionally) removably securing the first side of the panel within the frame; rotating the frame of the jig; removing the insert from the frame; positioning components of a second side of the panel within the frame; and assembling the components to complete the panel.

[0007] In some embodiments, a method for constructing a panel for a building sy stem can comprise: providing a jig having a frame rotatably coupled to a base and configured for vertical rotation with respect to two or more construction stations disposed on a floor around the jig; removably installing an insert within the frame of the jig, wherein the insert is configured to position components of the panel; and installing panel components at the two or more construction stations to construct the panel.

[0008] In some embodiments, a jig for constructing a panel can comprise: a base, and a frame rotatably coupled to the base for horizontal rotation. In some embodiments, the frame can be configured to removably retain an insert which is configured to position components of the panel within the frame for construction of one of the following: an exterior wall panel, an interior w all panel, a roof panel, or a foundation / floor panel. In some embodiments, the frame may comprise a centerline axis (e.g. a horizontal centerline axis), and the frame may be coupled to the base at the centerline axis. In some embodiments, the frame can be configured for at least 180 degree rotation, for example 360 degree rotation about the centerline axis.

[0009] These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] For a more complete understanding of the present disclosure, reference is now' made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

[0011] FIG. l is a perspective view of a base for an exemplary jig according to an embodiment of the disclosure.

[0012] FIG. 2 is a perspective view of the jig of FIG. 1 with an exemplary frame mounted (e.g. rotatably coupled for horizontal rotation) to the base, according to an embodiment of the disclosure.

[0013] FIG. 3 is a perspective view of the jig of FIG. 2 with an exemplary insert disposed within the frame according to an embodiment of the disclosure.

[0014] FIG. 4 is a perspective view' of construction of a first side of an exemplary' panel using the jig and insert of FIG. 3 according to an embodiment of the disclosure.

[0015] FIG. 5 is a perspective view of a completed first side of the panel (e.g. partial construction of the panel) of FIG. 4 according to an embodiment of the disclosure.

[0016] FIG. 6 is a perspective view of the jig with completed first side of the panel of FIG. 5, having an exemplary harness element removably attached to the frame, according to an embodiment of the disclosure.

[0017] FIG. 7 is a perspective view of the jig with first side of the panel of FIG. 6, after the frame has been rotated (e.g. flipped), according to an embodiment of the disclosure.

[0018] FIG. 8 is a perspective view of the jig of FIG. 7, after removal of the insert, according to an embodiment of the disclosure.

[0019] FIG. 9 is a perspective view of the jig of FIG. 8, in which the second side of the panel has been completed (e.g. so that the entire panel is completed), according to an embodiment of the disclosure.

[0020] FIG. 10 is a perspective view of the jig and completed panel of FIG. 9, with the panel / jig rotated to a vertical position, according to an embodiment of the disclosure.

[0021] FIG. 11 is a perspective view of the jig of FIG. 10, in which the harness element has been removed, according to an embodiment of the disclosure.

[0022] FIG. 12 is a perspective view illustrating removal of the completed panel from the jig of FIG. 11 according to an embodiment of the disclosure.

[0023] FIGS. 13-17 are perspective views illustrating construction of an exemplary panel using a jig system similar to that of FIGS. 1-12, in which the jig frame may be used to orient the panel vertically, according to an embodiment of the disclosure.

[0024] FIGS. 18-21 are perspective views illustrating an alternate exemplary' jig system, in which the panel can be oriented vertically during construction and may be configured to rotate about a vertical centerline axis, for example for rotation orientation towards (e.g. facing) a plurality of different work stations, according to an embodiment of the disclosure.

[0025] FIG. 22 is a flowchart illustrating an exemplary' embodiment of a method of making a side panel, according to an embodiment of the disclosure.

[0026] FIGS. 23-24 are perspective views illustrating an exemplary jig system configured for a type of roof panel, according to an embodiment of the disclosure.

[0027] FIGS. 25-33 are perspective views jointly illustrating an exemplary' method of constructing a roof panel, for example using a jig similar to that of FIG. 24, according to an embodiment of the disclosure.DETAILED DESCRIPTION

[0028] It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.

[0029] This disclosure pertains to the construction of panels for enclosed structures which may be utilized for a variety of purposes upon completion of their construction. For example, the enclosed structures may be utilized as a house or living space, an office, a storage unit, an entertainment room, or for other purposes. The enclosed structures may include access to one or more utilities (e.g.. electrical utilities, water, sewer, heating / air conditioning, etc.) to grant a user of the structure access to said utilities while within the structure. For example, the enclosed structures may include utilities, such as electrical outlets and / or an air conditioner to provide further utility to the structure. Additionally, the enclosed structures may be assembled at a variety7of locations for only a limited period of time before disassembly and transport to another location. The enclosed structures may be considered permanent structures on a permanent foundation while constructed, even while being dissembled and moved at a later time. The enclosed structures may be configured to be assembled with a minimum amount of tooling, making the disclosed enclosed structures relatively easy to assemble and disassemble.

[0030] Additionally, embodiments of the components formed using the jigs disclosed herein may comprise pre-fabricated components that can be packaged and shipped in specific combinations or kits, thereby allowing structures having a variety of dimensions and square footage to be assembled from the components while maintaining a minimum inventory for the manufacturer or supplier of the structures. In some contexts, this can be referred to as component construction, panel construction, or component construction (e.g. using pre-formed panels configured to be joined together to construct one or more enclosures). Further, a limited number of components / elements (e.g. panels) for component construction may be maintained to be used for the floor or foundation, the walls (interior and / or exterior), and the roof. While a limited number of components / elements may be used, a wide variety of structures and floorplans can be constructed from the components / elements. For example, an enclosed structure having a size of 10 feet (ft) by 10 ft providing 100 square ft of space may comprise one or more components / elements that may be used to assemble an enclosed structure having a size of, for example, 10 ft by 20 ft to provide a square footage of 200 ft. Given that the two differently sizedenclosed structures may share common components / elements (e.g. panels), the inventory required to supply these two separate structures may be minimized.

[0031] Additionally, a purchaser of an enclosed structure having a first square footage may be able to purchase one or more additional components / elements to reconfigure the structure to have a second square footage without needing to purchase an entirely new enclosed structure. In the event that the structure is to be removed, the components / elements (e.g. panels) can be disassembled and stored as components / elements, which may make long term storage of the structures easier and more convenient. Further, the storage of new or disassembled components / elements may allow for the structures to be staged in different locations in the event that the structures are needed on short notice. For example, in the event of an emergency, such as a hurricane, the components / elements can be used to construct housing for those affected by the storm, and after the housing need passes, the structures can be disassembled and stored for the next emergency. Examples of such enclosures and further details are illustrated in U.S. Prov. Patent Application 63 / 584,838 and U.S. Patent Application 18 / 248,236, both of which are fully incorporated herein.

[0032] By way of example, panels (e.g. components / elements for component construction) for constructing enclosures may include exterior panels (e g. exterior side wall panels), interior panels, roof panels, and / or foundation / flooring panels. Exterior panels may include an exterior surface (e.g. with sheathing such as siding, a window, and / or a door) and an interior surface (e.g. with wall coverings, such as drywall). Exterior panels may include insulation, for example between the interior and exterior surfaces. Interior panels may have wall coverings (e.g. dry wall) on both sides and / or may include a door or other opening.

[0033] FIGS. 1-11 illustrate an exemplary' system configured for constructing a panel for component construction. For example, the system may include a jig 201 having a base 105 and a frame 205 coupled to the base 105. The system may also include an insert 305 configured to position and / or support components of the panel for construction within the frame 205. The insert 305 may be separate and apart from the frame (e.g. a distinct and separate element), but be configured to be removably positionable within the frame. The frame 205 may be configured to removably retain the insert 305.

[0034] FIG. 1 illustrates an exemplary base 105 for the jig 201. Typically, the base 105 may be configured to be disposed on and / or mounted to a floor. In FIG. 1, the base 105 comprises a center support 107, configured to contact the floor, and two vertical supports 110, which may be configured to hold the frame 205 at an elevated position above the center support 107 and / or floor (e.g. to allow for horizontal rotation of the frame 205 with respect to the base 105). The centersupport 107 can extend between the two vertical supports 110, with an opening being formed between the two vertical supports 110 (e.g. which is sized for the frame 205). In some embodiments, the vertical supports 110 can be configured to hold a horizontal centerline axis 231 of the frame 205 at an elevated position. For example, the height of the vertical supports 110 may be greater than the distance between the horizontal centerline axis 231 and the edge of the frame 205 (e.g. greater than half of the side support 210 height of the frame 205). In some embodiments, the frame 205 can be configured to be extendable to accommodate manufacturing various size panels. For example, the height of the vertical supports 110 (or the attachment of the frame 205 to the vertical supports 110) can be adjustable and / or the width spacing of the vertical supports 110 (e.g. the distance therebetw een and / or the length of the center support 107) can be adjustable. In such embodiment, further support may be incorporated for stability. In some embodiments, the jig 201, base 105, and / or frame 205 can be movable to allow for emergency or '‘tent manufacturing”, wherein structural components, such as panels, are designed, manufactured, and / or assembled at the construction location to allow for fast construction. Tent manufacturing may be particularly helpful during natural disasters, wars, and other times when structures are needed imminently and efficiently.

[0035] Typically, the base 105 may comprise steel supports coupled (e.g. welded or bolted) together. For example, the center support 107 and the two vertical supports 110 may each be formed of steel and welded together to form the base 105. In some embodiments, a bushing 222 can be mounted to each vertical support 110 (e.g. and disposed vertically from the center support 107). In some embodiments, the base 105 may further comprise bracing 118 (e.g. configured to support the vertical supports 110). For example, bracing 118 may extend from the vertical supports 110. In some embodiments, the bracing 118 may extend on only one side of the center support 107 (e.g. providing a second side of the base 105 which is open for accessibility). In some embodiments, in addition to the bracing 118 extending on one side of the center support 107, for example approximately perpendicular to the center support 107, bracing 118 may also extend approximately parallel to the center support 107 (e.g. in line with the center support 107).

[0036] FIG. 2 illustrates an exemplary frame 205 coupled to the base 105 of FIG. 1. In embodiments, the frame 205 and / or corresponding insert 305 (see FIG. 3) can be configured for construction of one of the following: a side panel (e.g. an exterior wall panel, which may be solid, have a window, and / or have a door), an interior wall panel (e.g. which may be solid or have a door), a roof panel, or a foundation / floor panel. In FIG. 2, the frame 205 comprises an open rectangular structure / perimeter. for example having two approximately parallel side supports 210a, 210b and two approximately parallel span supports 215a, 215b which span therebetween (e.g. eachextending approximately perpendicular to the side supports 210). The opening of the frame 205 is disposed between the supports 210a. 210b. 215a, 215b, and can be sized for construction of the panel and / or for receipt of the corresponding insert 305. In some embodiments, the frame 205 and / or insert 305 can be extendable to accommodate various panel sizes. In such embodiments, more supports 210 and 215 may be utilized and / or supports 210 and 215 may be configured to mobilize to different locations for proper support.

[0037] In some embodiments, the side supports 210 can each be configured with a pin 220 extending outward therefrom approximately perpendicularly (e g. on opposite sides of the frame 205). For example, the pins 220 may be configured for coupling of the frame 205 to the vertical supports 110 of the base 105. for example with the pin 220 fitting within the corresponding bushings 222 on the vertical supports 110 of the base 105. In some embodiments, the pins 220 may be disposed on the horizontal centerline axis 231 of the frame 205. In some embodiments, when the frame 205 is mounted within the base 105, the bushings 222 may also be disposed on the horizontal centerline axis 231. In embodiments, the various frame 205 supports may include steel beams which are coupled (e.g. welded or bolted) together. In some embodiments, the frame 205 and / or the insert 305 can include a tray or an enclosure configured for containing materials, such as concrete, cement, or other materials, that are heavy and / or that may harden. For example, concrete, cement, or other pourable material which hardens can be poured onto the tray or into the enclosure. In some embodiments, the material may be allowed to harden therein (for example when the frame 205 is disposed in the horizontal position). In some embodiments, such hardening may take place before any rotation of the frame 205. In some embodiments, the frame 205 and / or insert 305 may be configured to allow for removal of the tray or enclosure after hardening.

[0038] In the embodiment of FIG. 2, the frame 205 comprises a centerline axis (e.g. a horizontal centerline axis 231). and the frame 205 is coupled to the base 105 at the centerline axis (e.g. with the pins 220 extending along the centerline axis). In some embodiments, the frame 205 can be rotatably coupled to the base 105. For example, the frame 205 may be configured for at least 180 degree rotation about the centerline axis (e g. in some embodiments approximately 360 degree rotation about the centerline axis). In the embodiment of FIG. 2, rotatable coupling of the frame 205 to the base 105 can be accomplished by disposing the pins 220 extending from the frame 205 within corresponding bushings 222 mounted on the base 105 (e.g. mounted on the vertical supports 110). In the embodiment of FIG. 2, the frame 205 can be rotatably coupled to the base 105 for horizontal rotation (e g. rotisserie-style, with the horizontal centerline axis 231 of rotation of the frame 205 elevated above and approximately parallel to the floor and / or center support 107). In other embodiments, the frame 205 may be fixed with respect to the base 105 (e.g. verticallyoriented, with the vertical orientation of the frame 205 allowing both sides of the panel to be worked on. for example simultaneously). In some embodiments, the frame 205 can comprise one or more openings (e.g. holes or slots in the supports) which may be configured to secure the insert 305 in place within the frame 205 and / or to allow for assembly of components of the panel within the frame 205 by providing access for attachment of components together (e.g. by nailing or screwing).

[0039] FIG. 3 illustrates an exemplary insert 305 disposed within the frame 205 of FIG. 2. The insert 305 can be removably retained in the frame 205. The insert 305 can be configured to position and / or support components of the panel for construction within the frame 205. For example, the insert 305 can comprise a plurality' of stops 315 which are configured for positioning and / or alignment of components within the frame 205 for construction of the panel. In some embodiments, the insert 305 further comprises a support layer 310, and the stops 315 extend (e.g. approximately perpendicularly) from the support layer 310. In some embodiments, the stops 315 extend from only one side of the support layer 310, for example towards the area that will become the interior space of the panel (e.g. between the interior and exterior surfaces of the panel).

[0040] In some embodiments, the stops 315 can be configured for positioning of panel components (e.g. structural / dimensional panel elements, such as lumber, a window, and / or a door), which may be configured to extend approximately parallel to the side supports 210 of the frame 205 and / or to extend approximately parallel to the span supports 215 of the frame 205. For example, as shown in FIG. 4, perimeter panel components (e.g. structural / dimensional framing lumber, although in other embodiments metal beams or other framing components may be used) may be disposed in contact with and / or approximately parallel to the side supports 210 and the span supports 215 (e.g. forming a rectangular perimeter for the panel), while other panel components (e.g. interior wall framing and / or structural / dimensional lumber) may be disposed within the frame 205 (e.g. within and / or attached to the perimeter of the panel) approximately parallel to the span supports 215. In some embodiments, the panel components (e.g. structural / dimensional lumber or other wall framing components) may be disposed atop the support layer 310 (e.g. with the support layer 310 configured to support the components when the frame 205 is in the first horizontal position, as shown in FIG. 4). So for example. FIG. 4 illustrates the use of the insert 305 within the frame 205 to construct the framing of the panel. In some embodiments, the insert 305 or the support layer 310 of the insert 305 may comprise steel beams coupled (e.g. welded or bolted) together.

[0041] In some embodiments, the support layer 310 may comprise a (e.g. rectangular) perimeter, which may be configured to fit snuggly in the opening of the frame 205 (for exampleabutting the supports of the frame 205). The perimeter of the support layer 310 may have an open space and a plurality (e.g. at least 2 or 3) of cross-supports 321 spanning the open space. In some embodiments, at least two of the plurality of cross-supports 321 are approximately parallel to each other. For example, in FIG. 3 the plurality of cross-supports 321 are all approximately parallel to each other. In some embodiments, at least two of the cross-supports 321 extend approximately parallel to the side supports 210 of the frame 205. For example, in FIG. 3 all of the plurality of cross-supports 321 extend approximately parallel to the side supports 210.

[0042] As shown in FIGS. 1-4, a motor 125 can be configured to rotate the frame 205 with respect to the base 105. This may allow for automatic positioning of the frame 205, rather than requiring manual rotation of the frame 205 during the construction process. Some embodiments may further include a pulley 127, with the motor 125 configured to rotate the frame 205 via the pulley 127. In some embodiments, the motor 125 and / or pulley 127 can be mounted to the base 105. In some embodiments, the base 105 may use a mechanical or hydraulic mechanism to move vertically at various height settings (e.g. an up and down vertical movement, for example of the vertical supports 110).

[0043] As illustrated in FIG. 5, the first side of the panel may be constructed using the insert 305 disposed (e.g. removably retained) within the frame 205 of the jig 201. For example, sheathing, trim, window(s) and / or door(s) may be assembled with (e.g. permanently affixed to, for example using nails or screws) the framing components (e.g. structural / dimensional lumber forming the framing of the panel). For example, after the panel framing has been constructed (see FIG. 4 for example), the remaining components of the first side of the panel may be installed (see FIG. 5 for example). In the embodiment of FIG. 5, the first side (e.g. the exterior side) of the panel has been completed.

[0044] As FIG. 6 illustrates, the system can also include one or more harness element 605 (or other mechanism) configured to removably hold / retain the panel (e.g. the partial panel, such as the first side of the panel during construction) onto the frame 205 (e.g. during rotation, as will be described in more detail below). FIG. 6 illustrates an embodiment having a plurality of harness elements 605, for example two harness elements 605. In some embodiments, the harness element(s) 605 can be configured to retain the panel (e.g. the first side of the panel during construction) in the frame 205 between the insert 305 and the harness element 605 (e.g. with positive contact on both sides of the panel). In some embodiments, the harness element 605 can removably couple to the frame 205 and / or can span the frame 205 (e.g. extending between the span supports 215 and / or approximately parallel to the side supports 210). For example, the harness element 605 can be configured to be coupled (e.g., hook, bolted, latched, etc.) about and / or ontothe span supports 215 of the frame 205. In embodiments, the harness element 605 may not be fixed to the insert 305. For example, the insert 305 may not be coupled to the panel or to the harness element 605, allow ing the insert 305 to be removable (e.g. for construction of the second side of the panel, as described in more detail below). Thus, the insert 305 of FIG. 6 can be removed from the frame 205, while the harness element 605 remains coupled to the frame 205 (for example after rotation of the frame 205).

[0045] Once the first side of the panel has been removably retained to the frame 205 (e.g. using the harness elements 605, as in FIG. 6), the second side of the panel may be constructed. In embodiments, the frame 205 may be rotated, which may provide improved access for construction of the second side of the panel and / or may allow for construction of the panel using a smaller footprint on the floor. For example, after the frame 205 of the jig 201 has been rotated (see for example, FIG. 7, in which the second side of the panel is exposed for work) the insert 305 may be removed as shown in FIG. 8. In some embodiments, the harness element 605 may support the first side of the panel after rotation, for example during construction of the second side of the panel. While there may be embodiments in which the frame 205 is configured to remain in the panel (e.g. providing framing and / or structural support), the embodiment of FIG. 8 illustrates removal of the insert 305 from the frame 205. Removing the insert 305 may allow' the same insert 305 to be used again (e.g. repeatedly) in the same or a similar jig 201 for forming another (e.g. substantially identical) panel and / or may expose the second side of the panel for construction (e.g. providing space for insulation for the panel, for example disposed within the panel framing, which can be formed by structural / dimensional lumber or light gauge steel).

[0046] Fig. 9 illustrates construction of the second side of the panel within the frame 205 (e.g. after the frame 205 has been rotated and / or the insert 305 has been removed). For example, insulation may be installed, and then sheathing / covering (e.g. wall coverings, such as sheet rock) and / or trim may be installed to form the second side of the panel (after which, the panel may be completely constructed).

[0047] In Fig. 9, the (e.g. completed) panel is disposed within the frame 205, and may be retained in the frame 205 using the one or more harness element 605. Depending on the type of panel being constructed using the jig 201 and insert 305. the panel may comprise one or more of the following: framing / structural / dimensional lumber, light gauge steel, or other framing components, sheathing or other covering (e.g. internal, such as sheet rock, and external, such as cladding or siding), trim (e.g. internal and / or external, for example at edges and / or around any door and / or window), a window, a door, and / or insulation). In some embodiments, the panel may include attachment / connection elements (e.g. connector elements), which may be configured tolink panels as part of the building process (see for example U.S. Prov. Patent Application 63 / 584.838 and U.S. Patent Application 18 / 248,236, both of which are fully incorporated herein). For example, the connector element(s) 570 can be incorporated into the panel(s), for example during the panel construction process. In some embodiments, the panel may include utilities, for example electrical connections. And in FIGS. 9-10, the panel is not fixed to the insert 305 (e.g. allowing for removal of the insert 305 from the frame 205, while the panel (or portion thereof, e.g. the first / front side of the panel during panel construction) remains disposed within the frame 205 (e.g. held / retained by the one or more harness element 605)).

[0048] In the embodiment of FIGS. 2-9, the frame 205 can be configured with a first horizontal position (e.g. for assembly of the first side of the panel - see FIGS. 3-5) and a second horizontal position (for assembly of the second side of the panel - see FIGS. 7-9). and the frame 205 may be rotatable between the two horizontal positions. For example, the first horizontal position and the second horizontal position may be 180 degrees of rotation apart, and the frame 205 may be rotated between the two. In some embodiments, the frame 205 may also have a vertical position, for example for removal and / or transport of the panel out of and / or away from the j ig 201. as illustrated FIGS. 10-12. For example, the frame 205 may be rotatable between the first horizontal position, the second horizontal position, and the vertical position.

[0049] In embodiments, once the panel construction is completed in the jig 201 (see Fig. 9), the frame 205 can be rotated to the vertical position of FIG. 10. The harness element(s) 605 can be removed (see FIG. 11), allowing removal of the completed panel 1212 from the frame 205 (see FIG. 12). The jig 201 can then be reset for reuse, for example for constructing another panel. By way of example, the frame 205 can be rotated from the vertical position of FIG. 12 back to the first horizontal position (e.g. see FIG. 2), and can then be reused with the insert 305 or a substantially similar insert to form a substantially identical panel for component construction. Alternatively, a different insert (e.g. configured for a different type of panel) could be used in the jig 201, for example to make different panels for the component construction system which are substantially the same size / configuration (e.g. with panels having substantially the same or uniform dimensions).

[0050] While FIGS. 2-12 illustrate an embodiment in which two horizontal positions are used for panel construction, FIGS. 13-17 illustrate a similar system (e.g. using a similar jig 201, for example configured for horizontal / rotissene-style rotation of the frame 205) having two vertical positions for construction of the panel. For example, the frame 205 of FIGS. 13-17 can comprise a first vertical position (for assembly of the first side of the panel - see for example FIGS. 13-14) and a second vertical position (for assembly of the second side of the panel and / or removal of thepanel from the jig 201 - see for example FIGS. 16-17), with the frame 205 rotatable therebetween. In embodiments, the first vertical position and the second vertical position may be approximately 180 degrees of rotation (e.g. of the frame 205 about the horizontal centerline axis) apart.

[0051] For example, the frame 205 may be oriented vertically (e.g. approximately perpendicular to the floor and / or central support and / or with the side supports 210 approximately parallel to the vertical supports 110) as shown in FIG. 13. The insert 305 can be installed in the frame 205, as in FIG. 14. The first side of the panel can be constructed within the frame 205 using the insert 305 (similar to the discussion above), and / or harness element(s) 605 can be coupled to the frame 205 to retain the first side of the panel within the frame 205 between the harness element 605 and the insert 305 (see FIG. 15 for example). The frame 205 can then be rotated from the first vertical position to the second vertical position (e.g. approximately 180 degrees of rotation therebetween), for construction of the second side of the panel (e.g. removal of the insert 305 and completion of the panel construction, as discussed above). The harness element 605 can be removed, as illustrated in FIG. 16, allowing for removal of the completed panel 1212 (see FIG. 17) from the jig 201.

[0052] In some embodiments, the vertical positioning of the frame 205 (e.g. the first and second vertical positions) can allow for both the first side and the second side of the panel to be assembled simultaneously. And in some embodiments, the frame 205 may further include a horizontal position (e.g. similar to that shown in FIGS. 2-3), for example for insertion of the insert 305 into the frame 205. For embodiments in which the frame 205 is rotatably coupled to the base 105, there may be rotation stops corresponding to the various horizontal and / or vertical positions of the frame 205 (e.g. allowing for precise positioning of the frame 205). In some embodiments, the motor 125 may be used to rotate the frame 205 between positions, and in some embodiments the motor 125 may be configured with pre-sets corresponding to the positions of the frame 205 during construction. In some embodiments with a vertical frame orientation, rotation may not be required, for example if both sides are accessible due to the vertical orientation of the frame 205. In such embodiments, rotation of the frame 205 may be an optional feature (e.g. in some embodiments, the frame 205 may be fixedly coupled to the base 105, for example in a vertical position).

[0053] The system described with respect to FIGS. 1-12 and / or FIGS. 13-17, or similar systems, can be used to more effectively construct panels, for example panels for component construction kits. In some embodiments, a different jig 201 and / or insert 305 may be configured for each type of panel for the component construction kit / system. In other embodiments (e.g. in which two or more of the panels have substantially identical external dimensions), the same (or anidentical) jig 201 can be used to construct different types of panels, for example by using different inserts 305 (each of which is configured for a different panel type or configuration) therein.

[0054] FIGS. 2-12 illustrate one such exemplar}' panel construction process using a jig 201. For example, a method for constructing / assembling a panel for a building system (e.g. a kit) may include the following steps: providing a jig 201 having a frame 205 rotatably coupled to a base 105 (see FIG. 2 for example); removably installing an insert 305 within the frame 205 of the jig 201 (see FIG. 3 for example), wherein the insert 305 is configured to support and / or position components of the panel (e.g. panel framing elements, such as structural / dimensional lumber) within the frame 205 (e.g. the insert 305 has a plurality of stops 315 for positioning components of the panel w ithin the frame 205); positioning components of a first / front side of the panel w ithin the frame 205 using the insert 305 (e.g. aligning the components with the stops 315 - see for example FIG. 4); assembling the components (e.g. permanently affixing, such as nailing or screwing the components together) to form the first side of the panel (see for example FIG. 5); removably securing the first side of the panel (e.g. the partially constructed panel) within the frame 205 (e.g. using a removable harness element 605 coupled to the frame 205 - see for example FIG. 6); rotating the frame 205 of the jig 201 (e.g. to provide second / back side access to the panel - see for example FIG. 7); removing the insert 305 from the frame 205 (see for example FIG. 8); and installing (e.g. positioning / assembling) second / back side components of the panel within the frame 205 (e.g. to complete the panel - see FIG. 9). Embodiments can further comprise unsecuring / releasing the panel from the frame 205 (e.g. removing the harness element 605 and / or making the panel removable from the frame 205 - see for example FIG. 11); and removing / withdrawing / transporting the completed panel 1212 from the frame 205 (see for example FIG. 12).

[0055] Some embodiments can further comprise resetting the jig 201 for construction of another (e.g. substantially identical) panel. For example, resetting the jig 201 can include reinstalling the insert 305 or a substantially similar insert within the frame 205 and / or repositioning the frame 205 into the initial (e.g. horizontal) position (e.g. similar to FIGS. 2-3). Alternatively, methods can include inserting a second, different insert 305 into the frame 205 of the jig 201 (e.g. to allow for construction of a second panel, different from the first using the same jig 201). In such embodiments, the first and second insert can have substantially similar exterior dimensions (e.g. perimeter), such that the first and second panel may be configured to have approximately the same exterior dimensions (e.g. perimeter).

[0056] In some embodiments, removably installing an insert 305 within the jig 201 (e.g. see FIG. 3) can comprise adjusting / setting a depth of the insert 305 within the frame 205 toaccommodate components (e.g. first / front side components) of the panel (e.g. so that when components are disposed atop the support layer 310. they are still disposed within the frame 205 - e.g. do not extend outwards beyond the frame 205). In some embodiments, positioning components of a first / front side of the panel within the frame 205 using the insert 305 can comprise positioning the components atop the insert 305 (e.g. atop a support layer 310 of the insert 305), and aligning the components using the stops 315 of the insert 305. See for example FIG. 4.

[0057] In some embodiments, rotating th e frame 205 can comprise rotating the frame 205 approximately 180 degrees. Rotating the frame 205 may occur before removing the insert 305 from the frame 205 and / or installing (e.g. positioning / assembling) second / back side components of the panel. In some embodiments (e.g. as shown in FIGS. 6-7), the jig 201 can be configured for horizontal rotation and / or rotating the frame 205 can comprise horizontally rotating the frame 205 about its horizontal centerline axis 231 (e.g. disposed approximately parallel to the floor.) Some embodiments may further comprise placing the frame 205 of the jig 201 in a first horizontal position (e.g. with the insert 305 approximately parallel to the floor - see FIG. 2 or 3 for example) before positioning / installing components of the first / front side of the panel and / or installing the insert 305 within the frame 205. For example, rotating the frame 205 of the jig 201 can then comprise rotating the frame 205 from the first horizontal position to a second horizontal position (e.g. approximately 180 degrees of rotation - see for example FIGS. 6-7). Some embodiments may further comprise rotating the frame 205 to a vertical position (see for example FIG. 10, in which the rotation to vertical position can occur before unsecuring the panel from the frame 205 (e.g. removal of the harness element 605)). The harness element(s) 605 can be removed, making the panel removable from the frame 205 - see FIG. 11), and the panel can then be released / removed from the frame 205 (see FIG. 12).

[0058] A similar process / method of construction can be used with the jig 201 of FIGS. 13-17 (e.g. having a first and second vertical position, for vertical assembly of the first and second side of the panel). Such methods may further comprise placing the frame 205 of the jig 201 in the first vertical position (e.g. with the insert 305 approximately perpendicular to the floor) before positioning / installing components of the first / front side of the panel within the frame 205 (see for example FIG. 14). Rotating the frame 205 of the jig 201 can then comprise rotating the frame 205 from the first vertical position to the second vertical position (e.g. approximately 180 degrees of rotation, with the insert 305 then approximately perpendicular to the floor again). Some embodiments may also (e.g. optionally) comprise rotating the frame 205 to a horizontal position (e.g. before removably installing an insert 305 within the frame 205 of the jig 201).

[0059] Regardless of the jig 201 / positioning variation, some method embodiments can further comprise anchoring the jig 201 (e.g. the base 105 of the jig 201) to the floor. Some embodiments can also comprise constructing the jig 201 (e.g. welding or coupling steel supports / members to form the base 105 (e.g. having a center support 107 and two vertical supports 110), welding / coupling steel supports / members to form the frame 205 (e.g. having two side supports 210 and two span supports 215), and rotatably coupling the frame 205 to the base 105 (e.g. for horizontal rotation of the frame 205). Embodiments may further comprise installing a motor 125 and / or pulley 127 configured to rotate the frame 205 with respect to the base 105.

[0060] Some embodiments may also include activating the motor 125 to rotate the frame 205 of the jig 201 (e.g. between positions). In some embodiments, an initial quality control check of the panel can be performed before rotating the frame 205 of the jig 201 (e.g. to provide second / back side access to the panel) and / or a second quality control check of the panel can be performed before removing the panel from the jig 201. Some embodiments may further include providing (e.g. configuring / constructing) the insert 305 (e.g. configured for one type of panel, such as an exterior wall panel (e.g. a side panel), an interior wall panel, a roof panel, or a foundation / flooring panel, or one configuration of panel (a solid panel, a panel with a window, a panel with a door. etc.). In some embodiments, configuring / constructing the insert 305 can comprise attaching a plurality of stops 315 extending from a support layer 310 (e.g. wherein the stops are positioned / oriented to position panel components within the frame).

[0061] FIGS. 18-21 illustrate another (e.g. alternative) exemplary panel construction system and method, for example using a jig 201 configured for vertical rotation. For example, the jig 201 may be configured so that the frame 205 is vertically rotatable with respect to the floor 1801, for example revolving-door-style (e.g. with the centerline axis of rotation approximately perpendicular to the floor 1801 and / or the center support 107 of the base 105). Similar to the discussion above, the jig 201 may include a frame 205 rotatably coupled to a base 105, but the centerline axis of rotation of the frame may be a vertical centerline axis 1831 (e.g. extending approximately vertically and / or perpendicular to the floor 1801). In some aspects, the embodiment of FIGS. 18-21 may be similar to the embodiments discussed above. However, there may be some differences (for example relating to the specifics of the jig 201) based on the different construction approach (e.g. with vertical rotation).

[0062] For example, in FIGS. 18-21 the base 105 can comprise two vertical supports 110 and a center support 107 extending between the vertical supports 110 at an elevated position above the floor 1801 and approximately parallel to the floor 1801. The center support 107 of the base 105 is elevated a distance above the floor 1801 greater than the height of the panel (e.g. the height ofthe side support 210 or the span support 215 of the panel, depending on orientation). The vertical supports 110, center support 107, and floor 1801 can together frame a rectangular opening sized for the frame 205 (e.g. larger than the frame 205). In some embodiments, corresponding pins 220 and bushings 222 can be used for rotatable coupling of the frame 205 to the base 105, for example with one of the bushings 222 extending (e.g. downward and / or within the base 105 perimeter) approximately perpendicular to the center support 107 (e.g. at approximately its center), and another of the bushings 222 extending (e.g. upward) approximately perpendicular to the floor 1801. The corresponding pins 220 on the frame 205 (e g. extending outward fromthe side supports 210) can be received within the bushings 222, which may provide rotational coupling of the frame 205 to the base 105 (e.g. allowing vertical rotation of the frame 205 about the vertical centerline axis 1831). In some embodiments, the bushings 222 and pins 220 can extend along the vertical centerline 1831 axis of the frame 205.

[0063] In some embodiments, the base 105 can further comprise bracing 118 (e.g. configured to support the vertical supports 110), although in other embodiments the base 105 may be fixed to the floor 1801. For example, the bracing 118 may extend on at least two sides of each vertical supports 110 (e.g. approximately perpendicular to the longitudinal axis of the center support 107). Optionally, the base 105 may comprise a second center support, extending across (e g. and in contact with) the floor 1801 betw een the two vertical supports 110 and approximately parallel to the first center support 107.

[0064] The system of FIGS. 18-21 can further comprise two or more stations or zones (e.g. construction stations) disposed on the floor 1801 around the jig 201 (e.g. at separate locations, for example separated by degrees of rotation), for example with the frame 205 configured to rotate for positioning with respect to the two or more stations or zones (e.g. so that the frame 205 can face the two or more stations, for example at different rotational positions of the frame 205). For example, in FIGS. 18-21 the system can comprise a framing station, which may have components (e.g. materials such as structural / dimensional lumber) and / or equipment (such as the insert 305 configured for positioning of the components in the frame 205) for framing the panel; an exterior installation station, which may have components (e.g. materials such as sheathing) and / or equipment (such as the harness element 605) for assembling the exterior side of the panel; an interior installation station, which may have components (e g. materials such as insulation and / or dryw all) and / or equipment (e.g. equipment for removing the insert 305) for assembling an interior side of the panel; and / or an offload station, which may be configured for removal of the harness element 605 and / or removal and transport of the completed panel 1212 away from the frame 205, for example including a transportation device (such as a forklift) for removing the completed panel1212 from the frame 205 and / or sufficient space for effective removal and transport of the panel. In some embodiments, the offload station may be configured to face a doorway, for example for storage or loading of the completed panel 1212 into transport vehicles. In some embodiments, a separate offload station may not be necessary; for example the completed panel may be removed and transported away without rotation away from the station at which panel construction is completed.

[0065] The frame 205 may be configured with rotational positions that correspond to (e.g. face towards) the various stations, and may be operable to rotate therebetween. For example, the frame 205 may comprise two or more of the following: an interior installation position (e.g. configured to face the interior installation station), an exterior installation position (e.g. configured to face the exterior installation station), a framing position (e.g. configured to face the framing station), and / or an offload position (e.g. configured to face the offload station). In embodiments, each station can be configured to store and / or organize the corresponding components and / or equipment which may be used at that station. In some embodiments, the two or more positions can be disposed around the jig 201 and / or can be spaced on the floor 1801 (e.g. approximately 90 degrees apart).

[0066] As shown in FIGS. 18-21. the framing station, the exterior installation station, the interior installation station, and the offload station can be disposed / spaced around the jig 201 (e.g. at separate locations on the floor 1801 around the base 105). In some embodiments, the framing station and the exterior installation station can be disposed adjacent one another on one side (e.g. a first side) of the base 105 of the jig 201, and the interior installation station and offload station can be disposed adjacent one another on another / opposite side (e g. a second side) of the base 105 of the jig 201. In some embodiments, the framing station and the exterior installation station can be disposed opposite one another (e.g. with the jig 201 disposed therebetween), and the interior installation station and the offload station can be opposite one another (e.g. with the jig 201 disposed therebetween). Vertical rotation of the frame 205 (e.g. about the vertical centerline axis 1831, revolving-door-style) can position / orient the frame 205 at the various stations and / or positions. In some embodiments, the frame 205 and / or insert 305 can be configured for use with only one type of panel. In other embodiments, the frame 205 can be configured to retain inserts for two or more different types of panels (e.g. which may have similar exterior dimensions).

[0067] Similar to the earlier discussion, the system of FIGS. 18-21 may include an insert 305 (e.g. configured to removably fit within the frame 205 and to position and / or support panel components during construction, for example of at least the first side of the panel). And in some embodiments, one or more harness element 605 can optionally be used to retain the partiallyconstructed panel within the frame 205 (e.g. with the first side of the panel disposed between the insert 305 and the harness element 605).

[0068] Considered jointly, FIGS. 18-21 illustrate another exemplary method for construction of a panel. For example, a method for constructing / assembling a panel for a building system may comprise: providing a jig 201 having a frame 205 rotatably coupled to a base 105 and configured for vertical rotation (e.g. about a vertical centerline axis 1831 approximately perpendicular to the floor 1801 and / or between two or more stations disposed (e.g. circumferentially) on the floor 1801 around the jig 201); removably installing an insert 305 within the frame 205 of the jig 201 , wherein the insert 305 is configured to support and / or position components of the panel (e.g. with the insert 305 having a plurality of stops 315 for positioning components of the panel, such as framing components); and installing panel components within the frame 205 at one or more station to construct the panel (e.g. using the insert for construction of at least one side of the panel). While some embodiments could have the frame 205 fixed within the base 105, and the panel could be constructed without rotation of the frame 205 (e.g. due to accessibility of both sides of the frame 205, for example potentially allowing simultaneous construction of both sides of the panel), the embodiment of FIGS. 18-21 involves rotation of the frame 205 (e.g. between a plurality of stations). In some embodiments, installing panel components at one or more station may comprise installing panel components at least two stations. For example, the method may include rotating the frame 205 between the at least two stations.

[0069] In some embodiments, installing panel components at one or more station can comprise: positioning components of a first station (e g. framing) within the frame 205 using the insert 305 (e.g. aligning the components with the stops 315); assembling the components of the first station (e.g. permanently affixing, such as nailing or screwing the components together); rotating the frame 205 of the jig 201 to a second station (e.g. exterior station); positioning components of the second station within the frame 205 (e.g. using the insert 305, for example by aligning the components with the stops 315 of the insert 305 and / or using the framing from the first station); assembling the components of the second station (e.g. permanently affixing, such as nailing or screwing the components together) to form the first side of the panel; rotating the frame 205 of the jig 201 to a third station (e.g. the interior station), which may provide second / back side access to the panel; removing the insert 305 from the frame 205; positioning components of the third station (e.g. interior) within the frame 205; and assembling the components of the third station (e.g. permanently affixing, such as nailing or screwing the components together), to complete construction / assembling of the panel. Some embodiments may also include removably securingthe panel within the frame 205 (e.g. using a removable harness element coupled to the frame 205), similar to that described above.

[0070] Some embodiments may further comprise rotating the frame 205 of the jig 201 to a fourth position (e.g. for offload of the panel), although in other embodiments the panel could be offloaded from the third position (or any other position). Some embodiments may further comprise unsecuring the panel from the frame 205 (e.g. removing the harness element and / or making the panel removable from the frame 205) and / or releasing / removing the completed panel 1212 from the frame 205 (e.g. at the fourth station). Some embodiments can further comprise resetting the jig 201 for construction of another (e.g. substantially identical) panel (e.g. rotating the frame 205 back to the first station and re-installing the insert 305 into the frame 205) or inserting a second, different insert 305 into the frame 205 of the jig 201 (e.g. to allow for construction of a second panel, different from the first, using the same jig 201, for example with the two different panels having substantially identical exterior dimensions / perimeters). In some embodiments, rotating the frame 205 can comprise rotating the frame 205 between adjacent stations (e.g. approximately 90 degrees). In some embodiments, the frame 205 can be rotated between each station, while in other embodiments less rotation may be necessary (for example if both sides of the panel can be simultaneously assembled using the jig 201, e.g. due to accessibility of both sides based on vertical orientation of the frame 205).

[0071] Some method embodiments can further comprise setting up the construction stations around the j ig 201. For example, embodiments may comprise setting up the first, second, and third (and in some embodiments, fourth) stations (e.g. providing the materials and / or equipment for each station, which may be disposed on the floor 1801 around the jig 201). In some embodiments, the jig 201 may be anchored to the floor 1801. Some embodiments can further comprise constructing the jig 201 (e.g. welding or coupling steel supports / members to form the base 105, welding / coupling steel supports / members to form the frame 205, and rotatably coupling the frame 205 to the base 105 (e.g. for vertical rotation of the frame 205). And as previously discussed, some embodiments may further comprise installing a motor 125 and / or pulley 127 configured to rotate the frame 205 with respect to the base 105.

[0072] In some embodiments, for example embodiments in which the frame 205 is oriented vertically (e g. approximately perpendicular to the floor 1801) no rotation may be necessary, for example due to accessibility of both sides of the jig 201 and / or panel. For example, the jig 201 may be configured so that the frame 205 does not rotate with respect to the base 105, with the frame 205 fixedly attached to the base 105. Construction may otherwise be similar to embodiments described herein (for example, using a removable insert in conjunction with theframe). In some embodiments, the first side and the second side of the panel may be constructed simultaneously. In some embodiments, the panel may be constructed without the need for rotation of the frame 205 and / or panel during the process (e.g. similar to method embodiments above, but without the rotation step(s)). Persons of skill will understand and appreciate the various embodiment variations arising from this disclosure, all of which are included within the scope of this disclosure. For example, aspects discussed with respect to one embodiment may alternately be used with aspects of another embodiment.

[0073] FIG. 22 illustrates an exemplary method embodiment for making an exemplary side panel, according to an embodiment of the disclosure. The method 2200 can be performed by a user of jig 201 to build a side panel, such as panel 1212. The method 2200 starts at step 2202 and proceeds to step 2204, where the base 105 is prepared. In one embodiment, the preparation of step 2204 can be accomplished by coupling or welding members to form the base 105 (e.g. having center support 107 and vertical supports 110). If more stability is desired, the base 105 may be anchored to the floor. If more accessibility is desired, bracing may be incorporated on only one side of the center support, to maintain clear accessibility from the opposite side. In some embodiments, the base 105 may be capable of shifting up and down vertically (e.g. the vertical supports 110 or the pins for coupling the frame 205 to the base 105 may be capable of shifting up and down vertically). At step 2206, the jig 201 is assembled by coupling or welding members to form the frame 205, and attaching the frame 205 to the base 105. In one embodiment, step 2206 may utilize a pin. such as pin 220, and bushing system to attach the jig frame 205 to the base 105 at each end, enabling the frame 205 to rotate 360 degrees like a rotisserie. In some embodiments, the frame 205 can include a tray or a flat base built into the frame 205 to allow for pouring materials such as concrete there onto.

[0074] From step 2206, the method proceeds to step 2208, wherein a motor and / or pulley system are installed. Jig 201 can be coupled with a pulley system and / or a motor to facilitate controlled rotational movement of the frame 205. At step 2208, the motor 125 may be used to position the frame 205 (e.g. approximately horizontally). At step 2210, the insert 305 can be installed in the jig 201, for example by positioning / placing a steel insert 305 (which may be prebuilt) within frame 205. In some embodiments, positioning the insert 305 may include adjusting its depth within the frame 205, for example to accommodate the wall materials / components during manufacture of the panel. At step 2212, the first side assembly for the panel can be performed by laying and aligning dimensional lumber within frame 205 on top of the insert 305. In embodiments, aligning dimensional lumber may include using stops 314 of the insert 305 to position the elements. In some embodiments, step 2212 includes coupling andassembling the wall components, such as framing lumber, sheathing, windows, doors, trim, and the like. In some embodiments, a harness may be used to removably hold the wall components and / or the insert 305 in place within the frame 205 (e.g. during rotation of the frame).

[0075] At step 2214, the second side of the panel is assembled by first accessing that second side. In some embodiments, frame 205 is rotated, for example, manually, using an electric motor, using a hydraulic mechanism, or the like, to allow for rotating of the inset 305 and / or wall components of the first side of the panel by the jig 201 (e.g. thereby exposing the second side of the panel for construction, for example by one or more user in the same space). In one embodiment, the jig 201 may rotate a full 360 degrees, and in others 180 degrees. When the second side of the panel is exposed, the first side points the other direction (e.g. opposite its original direction / facing). allowing access to the second side (e.g. without the user having to alter positions). In some embodiments, the insert 305 may need to be removed to allow access to the second side. In step 2214, the second side of the panel is assembled by installation of back components, which may include insulation, w all coverings, trim, and the like, to the back side. At step 2216, the panel is removed form the jig 201, for example by setting the jig 201 to a removal position. In some embodiments, the removal position is a vertical position that showcases the exterior side and / or that allows for easy removal of the panel. If a harness is used, the harness is removed to allow' for the removal of the panel form the jig 201. The method 2200 ends at step 2218.

[0076] While the panel shown as being constructed in FIGS. 3-21 is an exemplary exterior wall panel (e.g. a side panel), in other embodiments the panel can be an interior wall panel, a roof panel, or a foundation / flooring panel. In some embodiments, the jig 201 can be similar regardless of the type of panel (although in some embodiments, the frame 205 of the jig 201 may have different dimensions for different types of panels), with the specifics of the panel being implemented based on the specific configuration of the insert 305 for use in the frame 205 of the jig 201 (e.g. with the stops 315 of the insert 305 located for the specific panel being constructed) and / or the specific panel components used in constructing the panel (for example with exterior walls typically having insulation, while interior walls may not).

[0077] By way of example, the completed exterior wall panels (e.g. side panels) each may generally include (e.g. interior) support framing positioned between an interior covering or facade (e.g. interior surface) and an outer or external covering or facade (exterior surface). In some embodiments, a layer of insulation such as fiberglass insulation, foam panels, or injectable foam can be disposed between the interior covering or facade and the outer or external covering or facade in order to insulate the final structure. In some embodiments, the support framing may comprisea plurality' of beams, studs, or supports that can be formed from any suitable materials (e.g., steel, wood, etc.). For example, the support framing can be formed from steel beams or from wood (e.g., solid wood, engineered wood beams, mass timber beams, etc.). The plurality of beams, studs, or supports can be placed on standard spacing (e.g., 16 inch centers, etc.), and double header supports and / or double framing supports for openings can be used. One or more vertical studs can extend through the side panels to provide structural support to the support framing. When one or more opening are present (e.g. such as for a window or a door), double studs can be used with headers to form the openings with the proper structural support. The support framing can be joined together (e.g. permanently coupled) using any suitable mechanical couplings such as nails, screws, bolts, or the like. In some aspects, the mechanical couplings used to form the side panels can comprise screws to allow for a holding force (e.g. a tensile force) between a top and bottom of the support framing.

[0078] The support framing can generally be the same size regardless of the use of the side panels. For example, the side panel can be a door panel (e.g. a panel configured to have a door therethrough), a window panel (e.g. a panel configured to have a window therethrough), or a wall panel (e.g. a solid wall panel). Some embodiments of the side panel may include a first aperture and / or a second aperture, each aperture extending entirely through the support framing and coverings. In an embodiment, the first aperture may comprise a doorframe in which a door may be positioned to form a door panel while the second aperture may comprise a window frame in yvhich a window may be positioned to form a window panel.

[0079] Within the support framing, one or more couplings can be used to provide tie down support extending between a low er edge of the support framing and an upper edge of the support framing. One or more top couplings can be used to provide a fixed mechanical connection between the top support of the support framing and the vertical studs or headers (e.g. a roof panel, roof joist, and / or roof frame). One or more lower couplings can be used to provide a fixed mechanical connection between the bottom support framing and a floor (e.g. a foundation / flooring panel) when installed. The lower couplings can be coupled to a bottom support framing and / or the one or more vertical studs or headers. In some aspects, the lower couplings can be coupled to the same vertical studs as the one or more top couplings to provide a continuous tie down from the lower couplings through the top couplings to directly tie the roof joists to the floor and / or foundation in the final structure. The couplings can be formed from any suitable materials, and in some embodiments, the couplings can include metal strips or straps that can be coupled in a plurality of locations (e.g., on each end and / or in the middle) to the support framing using mechanical couplings such as screw s or nails.

[0080] In some aspects, weather stripping can be coupled to a lower edge of the support framing. The weather stripping can serve to direct any water or moisture outwards from the edge of the support framing, thereby keeping the materials of the support framing dry when exposed to the weather. The weather stripping can comprise an upper portion coupled to the support framing and a lower portion that extends outwards from the support framing to serve as a drip edge. The weather stripping can be formed from any suitable materials such as metal (e.g., galvanized steel, etc.), plash c, concrete board, or the like. The weather stripping can be coupled to the lower portion of the support framing using any suitable couplings such as nails, screws, or the like, and in some aspects, a sealant may be used between the weather stripping and the support framing.

[0081] The interior covering for the side panel may comprise a material such as a laminate, pre-constructed shiplap, sheet rock, or other materials; however, in other embodiments, the configuration of interior covering may vary. For example, the interior covering may comprise plywood in other embodiments. Additionally, a sealant and / or a decorativ e material may be applied to interior covering. The interior covering may provide cover to the support framing on an interior surface of the enclosed structure.

[0082] The exterior covering for the side panel may comprise a material such as a laminate, pre-constructed shiplap, plywood, concrete board, or the like. In some aspects, the exterior covering may comprise plywood to provide structural support to the side panel while also allowing an additional exterior covering to be coupled to the exterior covering in some embodiments. The exterior covering may provide cover to the support framing on an exterior surface of the enclosed structure. When installed, the weather stripping can be positioned between the support framing and the exterior covering, or on an exterior of the exterior covering. In some aspects, the weather stripping can be positioned between the support framing and the exterior covering. In some embodiments, an upper portion of the support framing can be left exposed by the exterior covering, for example to allow the roof joists to be coupled to the support framing during installation.

[0083] In some embodiments, an additional siding material may be applied to the exterior covering. The siding material can comprise a w eather proofing material such as plastic or w ooden siding, laminate, concrete based siding, shiplap. metal siding, or the like. In some aspects, an exterior vapor barrier can be installed between the exterior covering and the siding material. In some embodiments, the siding material can be positioned on an exterior surface of the exterior covering, and / or the weather stripping can be positioned between the siding material and the support framing. This positioning can direct any water down the drip edge rather than allowing any water to contact the exterior covering or the support framing. The lower couplings can alsobe left exposed in the side panels to allow the lower couplings to be coupled to the floor assembly during installation.

[0084] An insulating layer can be formed or placed into the support framing (e.g. when only a first side of the panel is closed by a covering, and the second side of the panel is open) to insulate the side panel. The insulation can be positioned within the support framing and may extend between the interior covering and the exterior covering. The insulation can include roll insulation (e.g.. fiberglass, natural fibers, foam sheeting, etc.), spray insulation (e.g.. foam, etc.), or combinations thereof. The insulation can be placed around the various supports (e.g. of the support framing) when installed.

[0085] The size of the side panels can generally be the same for each of the different types of panels (e.g. solid wall panels, window panels, or door panels). In some aspects, the side panels can have an approximate size of 6 feet by 8 feet, and the floor assembly / panel may have a size of 6 feet by 12 feet. In some aspects, the side panels can have a width approximately equal to a smaller dimension of the floor assembly / panel, and the floor assembly / panel may have a width to length ratio of 1 : 2. This can allow the edges of the side panels to align with the foundation supports and / or couplings between adjacent floor assemblies / panels so that a variety of sizes and shapes of enclosed structures can be formed using a limited number of panels.

[0086] In some embodiments, one or more of the panels can be constructed (in whole or in part) offsite and transported to the construction site for the enclosed structure. For example, the corresponding jig (including the insert) could be used offsite to construct the panel(s) for shipment to the construction site. In some embodiments, the panels would be complete (e.g. when offloaded from the jig), and construction at the site would involve coupling the side panels together (and in some embodiments with flooring panels and / or roofing panels) to form the enclosed structure. In some embodiments, the panels may be only partially completed using an offsite jig. and the panels may be completed on site (e.g. to allow for onsite customization). For example, a plurality of panels can be prepared as part of a kit comprising the support framing, the interior covering, the weather stripping, the top couplings, and the lower couplings. In some embodiments, the kit can comprise one or more door panels, one or more window panels, and one or more wall panels. In some embodiments, the addition of insulation, exterior covering, and / or siding can be performed at the construction location / site.

[0087] In other embodiments, one or more of the panels can be constructed onsite. For example, the corresponding jig (e.g. including the insert) may be disposed at the construction site for the enclosed structure and the panels may be constructed onsite using the jig. In such instances, no completed panels may be transported to the site. Rather, the jig (or the parts and / or plans forconstruction of the jig onsite) can be delivered onsite. In some embodiments, the corresponding insert may be delivered onsite, along with instructions for forming the jig for use therewith. The components (e.g. for use with the jig to construct the panel) can also be delivered onsite. The jig may then be used to assemble the components onsite into the panels for the component construction project (e.g. to construct the enclosed structure). In some embodiments, the jig (including the corresponding insert for the panel) may serve as a template for construction of panels. A limited number of such templates may provide the various panels (e.g. exterior wall panels, interior wall panels, foundation / flooring panels, and / or roof panels) used for the component construction project, which may greatly simplify the construction process for the enclosed structure and / or provide cost and time savings.

[0088] While some roof panel embodiments may be substantially flat and / or may be constructed similar to the discussion regarding FIGS. 1-21, other roof panel embodiments may comprise a plurality of trusses (e.g. and may have a triangular cross-section). FIGS. 23-32 illustrate an exemplary jig configured for construction of such an exemplary' roof panel, and jointly these figures illustrate an exemplary method of construction of roof panels using such a jig. For example. FIG. 23 illustrates an exemplary jig 2301 for a roof panel having a base 2305 and a plurality of vertical supports 2310 each configured to removably couple to the base 2305. Each vertical support 2310 in FIG. 23 comprises a plurality of truss supports 2315 extending from an interior surface 2312 of the corresponding vertical support 2310, and the plurality of truss supports 2315 for each vertical support 2310 are vertically spaced apart. In some embodiments, the base 2305 may be configured to support a truss of the roof panel (e g. approximately parallel to the floor), for example during construction of the panel (see for example FIG. 25). In embodiments, the base 2305 may be sized and / or shaped based on the trusses for the roof panel and / or the locations at which the vertical supports 2310 couple to the base 2305 may be based on the specifics of the trusses for the roof panel (e.g. so that the truss supports 2315 can effectively support the busses at the specific elevations for the roof panel during construction).

[0089] In some embodiments, each vertical support 2310 may comprise a base support 2317 (e.g. disposed in proximity to its bottom) configured to removably attach to a corresponding base receptacle 2307 (e.g. a corresponding connector for the base support 2317, disposed on the base 2305), for example with the base support 2317 sliding into or onto the corresponding base receptacle 2307. In some embodiments, each vertical support 2310 may further comprise bracing 2318 configured to support the vertical support 2310 in an upright position when the vertical support 2310 is removably coupled to the base 2305. In FIG. 23, each truss support 2315 may include an upper support surface 2316, which can be approximately parallel to the floor and / orwhich can be configured to support a portion of a structural roof support / framing element (e.g. such as a joist or a rafter) for forming a truss.

[0090] In embodiments, the truss supports 2315 of the plurality of vertical supports 2310 which are disposed at the same elevation (e.g. vertically above the base 2305 and / or floor) are configured to jointly support / hold a truss (e g. during construction of the roof panel). For example, a truss in the jig 2301 can be oriented approximately parallel to the floor and / or the base 2305. The jig 2301 may be configured (e.g. with multiple horizontal levels of truss supports 2315 vertically spaced) to hold a plurality of roof trusses during construction of the roof panel. In some embodiments (e.g. as shown in FIG. 23) the truss supports 2315 on all of the vertical supports 2310 are identically spaced (e.g. each vertical support 2310 is substantially identical). In some embodiments, the truss supports 2315 on each vertical support 2310 are approximately equally spaced (e.g. allowing a plurality of roof trusses to be held vertically spaced, for example with even vertical spacing therebetween). Typically, the plurality of trusses may be held in the jig 2301 with vertical spacing therebetween, for example with all of the trusses in the jig 2301 approximately parallel to the floor and / or base 2305 (e.g. horizontally oriented at different elevations). The spacing of the truss supports 2315 may be configured to space the trusses within the jig 2301 as needed for construction of the roof panel, and the trusses may all be held in the same orientation (e.g. providing substantially identical stacked levels of trusses within the jig 2301 during construction).

[0091] In embodiments, each vertical support 2310 can have 2-8. 3-6, or 3-4 truss supports. For example, in FIG. 23, the plurality of vertical supports 2310 comprises three vertical supports (e.g. disposed above the base support 2317). In some embodiments, two of the vertical supports 2310 can be disposed on one side of the base 2305 (e.g. in proximity' to the ends of the base) and one vertical support 2310 can be disposed on the opposite side of the base 2305 (e.g. in proximity to the longitudinal midpoint / center of the base). For example, in FIG. 23, the base 2305 comprises a first side 2308 and a second side 2309 (e.g. opposite the first side 2308), with two vertical supports 2310 disposed on (e.g. removably coupled to) the first side 2308, and one vertical support disposed on (e.g. fixedly or removably coupled to) the second side 2309. In FIG. 23, the first and second sides 2308, 2309 are each longitudinal sides of the jig 2301 / base 2305. In FIG. 23, the two vertical supports 2310 on the first side 2308 of the base 2305 can be disposed in proximity to the two ends of the first side 2308, and the vertical support 2310 on the second side 2309 can be disposed in proximity' to the midpoint / center of the second side 2309. In some embodiments, all of the vertical supports 2310 may be removably coupled to the base 2305. In other embodiments, only two of the vertical supports 2310 (e.g. the two vertical supports on the first side 2308) maybe removably coupled to the base 2305, while one vertical support 2310 (e.g. the vertical support on the second side 2309) may be fixedly coupled to the base 2305. In some embodiments, each vertical support 2310 may be formed of steel tubing, for example with the truss supports 2315 and / or bracing 2318 welded to the vertical support 2310.

[0092] In some embodiments, the base 2305 may be formed of a plurality of steel supports / beams coupled (e.g. welded) together into an integral whole. For example, the base 2305 may include a perimeter and a plurality of bracing supports (e.g. extending from the first side 2308 to the second side 2309). In some embodiments, further supports may be included within the perimeter of the base 2305, which may provide additional structural rigidity and / or strength to the base 2305 and / or may provide support for the rafters and / or joist of the truss. In some embodiments, the base 2305 can be configured to rotate on the floor. For example, the base 2305 may include a plurality of wheels / rollers 2330 (e.g. disposed on its bottom surface for contact with the floor). In some embodiments, the wheels 2330 may comprise casters (e.g. wheels configured to rotate about the connection point), allowing 360 degree movement. In some embodiments, the base 2305 may have one or more stop mechanism 2333 configured with a first position allowing free rotation of the base and a second position impeding rotation of the base. For example, in FIG. 23 the one or more stop mechanism 2333 may be configured as a lever having a retracted position (e.g. away from the floor) and an extended position (e.g. contacting the floor) and / or may include a friction surface at its distal end configured to create a locking force due to friction with the floor (e.g. similar to a bicycle stand). In other embodiments, the one or more stop mechanism 2333 may be disposed on the wheel 2330, for example as a wheel lock preventing rotation of the wheel 2330 with respect to the floor.

[0093] FIGS. 23-32 jointly illustrate an exemplary method for constructing a roof panel using ajig 2301 similar to that discussed above with respect to FIG. 23. For example, the method may comprise: providing ajig 2301 (e.g. similar to that described above with respect to FIG. 23) with a plurality of vertical supports 2310 removably coupled to a base 2305 (e.g. see FIGS. 23-24); providing a first truss 2550 within the jig 2301 atop the base 2305 (e.g. approximately parallel to the floor - see for example FIG. 25); providing within the jig 2301 one or more additional truss 2550 (e.g. in FIGS. 26-28, three additional trusses 2550 b, c. d) vertically spaced (e.g. at different elevations) above the base 2305 (e g. with the plurality of truss supports 2315 at the same elevation level supporting each such truss 2550 and / or with such one or more additional truss 2550 b, c, d approximately parallel to the base 2305, the floor, and / or the first truss 2550a); coupling decking 2980 (e.g. exterior sheathing, such as plywood) to the trusses 2550 in the jig 2301 (e.g. coupling the decking 2980 to the rafters 2560 of the trusses 2550 , with the decking 2980 spanning all ofthe trusses 2550 - see for example FIG. 29); insulating the roof panel (e.g. inserting insulation 3113 between the trusses 2550 - see for example FIG. 31); and coupling interior sheathing 3218 (e.g. ceiling covering, such as sheetrock) to the trusses 2550 in the jig 2301 (e.g. coupling the interior sheathing 3218 to the joists 2555 of the trusses 2550, with the interior sheathing 3218 spanning all of the trusses 2550 - see for example FIG. 32). In some embodiments, the interior sheathing 3218 may not extend to the ends of the roof panel / trusses (e.g. such that the joists 2555 may be exposed, for example at the ends, to simplify coupling of the trusses 2550 to the side walls during construction of an enclosure). Some embodiments may further comprise removing at least two of the vertical supports 2310 (and in some embodiments, all of the vertical supports) from the base 2305 (e.g. after construction of the roof panel within the jig 2301 is complete), such that the roof panel may be supported by / rest atop the base 2305. For example, after removal of the vertical supports 2310, the roof panel may be entirely supported by the base 2305. Some embodiments may further comprise coupling roofing material (such as shingles or metal roofing) atop the decking 2980.

[0094] Some embodiments may further comprise rotating the jig (e.g. approximately 180 degrees or up to 360 degrees) during panel construction (e.g. rotating the jig at least 180 degrees for each truss 2550 being constructed, and in some instances having two 180-degree rotations for each truss 2550). Some embodiments may further comprise releasing the stops mechanism(s) 2333 of the base 2305 (e.g. moving the stop mechanisms 2333 to their first position), before rotating the jig 2301 and / or locking the stop mechanisms 2333 (e.g. moving the stop mechanisms 2333 to their second position) after rotation of the jig 2301. Some embodiments may further comprise, using the wheeled jig 2301 to transport the completed panel (e.g. rolling the panel using the jig 2301). In some embodiments, providing the jig 2301 may comprise providing the base 2305. providing the plurality of vertical supports 2310, and removably coupling the plurality of vertical supports 2310 to the base 2305. Some method embodiments may further comprise resetting the jig 2301 for construction of another (e.g. second) roof panel. For example, embodiments may include re-coupling the vertical supports 2310 to the base 2305 (for example, after removal of the completed panel from the jig 2301) and / or rotating the jig 2301 to its initial position (e.g. using the wheels 2330).

[0095] In some embodiments, providing a truss 2550 (e g. either the first truss or one or more additional truss) may comprise positioning a pre-formed truss 2550 within the jig 2301 (e.g. atop the base 2305 or the truss supports 2315 in a horizontal plane elevated above the base 2305). In some embodiments, providing a truss 2550 may comprise constructing a truss. For example, constructing a first truss 2550a may comprise disposing a joist 2555 and two rafters 2560a, b onthe base 2305 (e.g. to form a triangular shape), and coupling the joist 2555 and rafters 2560 together to form the truss 2550. Some embodiments may further comprise coupling a strut 2570 extending between the joist 2555 and the rafters 2560 (e.g. in proximity to where the two rafters 2360 meet and / or the midline of the truss 2550). For each additional truss 2550 b, c, d, constructing can comprise disposing a joist 2555 and two rafters 2560 in a (e.g. substantially horizontal) plane above the base 2305 (e.g. using the truss supports 2315 in that horizontal plane), for example to form a triangular shape and / or a shape substantially identical to that of the first truss 2550a and / or oriented the same way as the first truss 2550a) and coupling the j oist 2555 and rafters 2560 together to form the truss. And again, some embodiments may also comprise coupling a strut 2570 extending between the joist 2555 and the rafters 2560 for each additional truss.

[0096] As shown in FIGS. 25-28, after positioning / construction of the first truss 2550a atop the base, the second truss 2550b can then be positioned / completed within the jig 2301, followed by the third truss 2550c and then the fourth truss 2550d. Some embodiments may further comprise coupling the trusses 2550 a, b, c, d together using a plurality of cross-supports 3085 (e.g. configured to extend across the vertical spacing between adjacent trusses, for example approximately perpendicular to the trusses - see for example FIG. 30). In embodiments, some cross-supports 3085 can be disposed in proximity to the ends of the roof panel and / or one or more cross-support 3085 can be disposed in proximity to the middle / center of the roof panel (e.g. extending approximately perpendicularly from the midpoint of the first side of the trusses and / or disposed in proximity’ to the struts).

[0097] Accordingly, roof panels may be constructed using ajig 2301 . The same jig 2301 may be used to construct multiple roof panels, which all may be substantially identical in size, shape, and / or construction (e.g. materials). In some embodiments, the jig 2301 may be set up to serve as a template for constructing a specific roof panel. In some embodiments, the jig 2301 can be changed to serve as a template for a different roof panel by changing out the vertical supports 2310 previously used for different vertical supports (e.g. with different length and / or different number and / or spacing of the truss supports 2315). For example, by using the same base 2305 with different vertical supports, different size roofing panels with the same overall truss geometry can be formed (e.g. panels having different number of trusses).

[0098] In embodiments, the various panels described herein may be used as part of a component construction system, for example configured to build an enclosed structure (e.g. as described in more detail in U.S. Prov. Patent Application 63 / 584,838 and U.S. Patent Application 18 / 248.236, both of which are fully incorporated herein). For example, the enclosed structure may comprise a floor assembly (e.g. comprising one or more flooring panel) positioned on a foundation,a plurality of first side panels (e.g. external wall panels with a first configuration), one or more second side panel (e.g. external wall panel of a different, second configuration), and a roof assembly (e.g. formed of one or more roofing panel and / or roof truss). In some embodiments, the enclosed structure may include one or more interior wall panels. The enclosed structure may comprise a kit that can be shipped as a set of floor panels, side (e.g. exterior wall) panels, interior wall panels, and / or roof panels to be assembled, and thus may also be referred to herein as a kit for assembling an enclosed structure.

[0099] The panels may be configured for connection, for improved assembly of the enclosed structure. In some embodiments, the same panels may be used in different kits (e.g. for different enclosed structures) and / or additional panels may be added to alter an enclosed structure (e.g. for enlarging the enclosed structure). In some embodiments, all of the same type of panel for an enclosed structure and / or kit may have substantially identical exterior dimensions. For example, all exterior wall panels (e.g. side panels) may be substantially the same size (e.g. uniform in size), all interior wall panels may be substantially the same size (e.g. uniform in size), all floor panels may be substantially the same size (e.g. uniform in size), and / or all roof panels may be substantially the same size (e.g. uniform in size). In some embodiments, two or more of the different types of panels may have substantially identical exterior dimensions.ADDITIONAL DISCLOSURE

[0100] The following are non-limiting, specific embodiments / aspects in accordance with the present disclosure:

[0101] In a first aspect, a system for constructing a panel (e g. for component construction) can comprise: a jig having a base and a frame coupled to the base; and an insert configured to position components of the panel within the frame; w herein the frame is configured to removably retain the insert.

[0102] A second aspect can include the system of the first aspect, wherein the insert is configured for construction of one of the following: an exterior wall panel, an interior w all panel, a roof panel, or a foundation / floor panel.

[0103] A third aspect can include the system of the first or second aspect wherein: the frame comprises a horizontal centerline axis and the frame is rotatably coupled to the base at the horizontal centerline axis for horizontal rotation; and the frame is configured for at least 180- degree rotation (and in some aspects, 360-degree rotation).

[0104] A fourth aspect can include the system of any one of the first to third aspects, wherein the insert comprises a plurality of stops which are configured for positioning components withinthe frame for construction of the panel; the insert further comprises a support layer; and the stops extend from the support layer.

[0105] A fifth aspect can include the system of any one of the first to fourth aspects, wherein: the base comprises a center support configured to contact the floor and two vertical supports; the center support extends between the two vertical supports; the vertical supports are configured to hold the frame at an elevated position above the center support; and the frame is rotatably coupled to the vertical supports.

[0106] A sixth aspect can include the system of the fifth aspect, wherein the base further comprises bracing, and wherein the bracing extends on only one side of the center support.

[0107] A seventh aspect can include the system of any one of the first to second aspects, wherein the frame comprises a vertical centerline axis, and the frame is rotatably coupled to the base at the vertical centerline axis for vertical rotation.

[0108] An eighth aspect can include the system of the seventh aspect, wherein the base comprises two vertical supports and a center support extending between the vertical supports at an elevated position above the floor; and wherein the frame is rotatably coupled to the center support.

[0109] A ninth aspect can include the system of any one of the seventh to eighth aspects, further comprising two or more stations disposed on a floor around the jig, wherein the frame is configured to rotate for positioning with respect to the two or more stations.

[0110] A tenth aspect can include the system of any one of the first to ninth aspects, further comprising one or more harness element configured to removably hold the panel during construction in the frame between the insert and the harness element.

[0111] In an eleventh aspect, a method for constructing a panel for a building system can comprise: providing a jig having a frame rotatably coupled to a base; removably installing an insert within the frame of the jig, wherein the insert is configured to position components of the panel within the frame; positioning components of a first side of the panel within the frame using the insert; assembling the components to form the first side of the panel; removably securing the first side of the panel within the frame; rotating the frame of the jig; removing the insert from the frame; positioning components of a second side of the panel within the frame; and assembling the components of the second side to complete the panel.

[0112] A twelfth aspect can include the method of the eleventh aspect, further comprising unsecuring the panel from the frame; removing the panel from the frame; and resetting the jig for construction of another substantially identical panel.

[0113] A thirteenth aspect can include the method of any one of the eleventh to twelfth aspects, wherein the insert comprises a plurality of stops extending from a support layer, which areconfigured for positioning components of the panel within the frame; and wherein positioning components of a first side of the panel within the frame using the insert comprises positioning the components atop the support layer and aligning the components using the stops of the insert.

[0114] A fourteenth aspect can include the method of any one of the eleventh to thirteenth aspects, wherein rotating the frame comprises horizontally rotating the frame approximately 180 degrees, and wherein rotating the frame occurs before positioning components of a second side of the panel.

[0115] A fifteenth aspect can include the method of any one of the eleventh to fourteenth aspects, further comprising placing the frame of the jig in a first horizontal position before positioning components of a first side of the panel within the frame using the insert, wherein rotating the frame of the jig comprises rotating the frame from the first horizontal position to a second horizontal position.

[0116] A sixteenth aspect can include the method of any one of the eleventh to thirteenth aspects, further comprising placing the frame of the jig in a first vertical position before positioning components of a first side of the panel, wherein rotating the frame of the jig comprises rotating the frame from the first vertical position to a second vertical position.

[0117] In a seventeenth aspect, a method for constructing a panel for a building system can comprise: providing a jig having a frame rotatably coupled to a base and configured for vertical rotation with respect to two or more construction stations disposed on a floor around the jig; removably installing an insert within the frame of the jig. wherein the insert is configured to position components of the panel; and installing panel components at the two or more construction stations to construct the panel.

[0118] An eighteenth aspect can include the method of the seventeenth aspect, wherein installing panel components at the two or more stations comprises: positioning components of a first station within the frame using the insert; assembling the components of the first station; rotating the frame of the jig to a second station; positioning components of the second station within the frame; assembling the components of the second station; rotating the frame of the jig to a third station; removing the insert from the frame; positioning components of the third station within the frame; and assembling the components of the third station to complete construction of the panel.

[0119] A nineteenth aspect can include the method of the eighteenth aspect, further comprising releasing the panel from the frame; and resetting the jig for construction of another panel byrotating the frame back to the first station and re-installing the insert into the frame.

[0120] A twentieth aspect can include the method of any one of the seventeenth to nineteenth aspects, wherein both sides of the panel can be simultaneously constructed using the jig.

[0121] In a twenty -first aspect, a jig for constructing a panel can comprise: a base; and a frame rotatably coupled to the base for horizontal rotation; wherein: the frame is configured to removably retain an insert which is configured to position components of the panel within the frame for construction of one of the following: an exterior wall panel, an interior wall panel, a roof panel, or a foundation / flooring panel; the frame comprises a centerline axis, and the frame is coupled to the base at the centerline axis; and the frame is configured for 360 degree rotation about the centerline axis.

[0122] A twenty-second aspect can include the jig of the twenty-first aspect, wherein: the base comprises a center support, configured to contact the floor, and two vertical supports; the center support extends between the two vertical supports; the vertical supports are configured to hold the frame at an elevated position above the center support; and the frame is rotatably coupled to the vertical supports.

[0123] A twenty-third aspect can include the jig of the twenty-second aspect, wherein the base further comprises bracing, and wherein the bracing extends on only one side of the center support.

[0124] While embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of this disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and are within the scope of this disclosure. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented. Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other techniques, systems, subsystems, or methods without departing from the scope of this disclosure. Other items shown or discussed as directly coupled or connected or communicating with each other may be indirectly coupled, connected, or communicated with, for example through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise.

[0125] Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein. Method or process steps set forth may be performed in a different order. The use of terms, such as “first,’' “second,"’ “third"’ or “fourth” to describe various processes or structures is only used as a shorthand reference to such steps / structures and does not necessarily imply that suchsteps / structures are performed / formed in that ordered sequence (unless such requirement is clearly stated explicitly in the specification).

[0126] Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, Rl, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R1 +k* (Ru-Rl), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent. 4 percent, 5 percent, . 50 percent,51 percent. 52 percent, . , 95 percent. 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Language of degree used herein, such as “approximately,” “about,” “generally,” and “substantially,” represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the language of degree may mean a range of values as understood by a person of skill or, otherwise, an amount that is + / -10%.

[0127] Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. When a feature is described as “optional.” both embodiments with this feature and embodiments without this feature are disclosed. Similarly, the present disclosure contemplates embodiments where this “optional” feature is required and embodiments where this feature is specifically excluded.

[0128] Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow-, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as embodiments of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The discussion of a reference herein is not an admission that it is prior art, especially any reference that can have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.

[0129] Use of the phrase “at least one of’ preceding a list with the conjunction “and” should not be treated as an exclusive list and should not be construed as a list of categories with one itemfrom each category, unless specifically stated otherw ise. A clause that recites “at least one of A, B, and C” can be infringed with only one of the listed items, multiple of the listed items, and one or more of the items in the list and another item not listed.

[0130] As used herein, the term “or” is inclusive unless otherwise explicitly noted. Thus, the phrase “at least one of A, B, or C” is satisfied by any element from the set {A, B, C} or any combination thereof, including multiples of any element.

[0131] As used herein, the term “and / or” includes any combination of the elements associated with the “and / or” term. Thus, the phrase “A, B, and / or C” includes any of A alone, B alone, C alone, A and B together, B and C together, A and C together, or A, B, and C together.

Claims

CLAIMSWhat is claimed is:

1. A system for constructing a panel for component construction, comprising: a jig having a base and a frame coupled to the base; and an insert configured to position components of the panel within the frame; wherein the frame is configured to removably retain the insert.

2. The system of claim 1, wherein the insert is configured for construction of one of the following: an exterior wall panel, an interior wall panel, a roof panel, or a flooring panel.

3. The system of claim 1 wherein: the frame comprises a horizontal centerline axis; the frame is rotatably coupled to the base at the horizontal centerline axis for horizontal rotation; and the frame is configured for at least 180 degree rotation.

4. The system of claim 1, wherein: the insert comprises a plurality of stops which are configured for positioning components within the frame for construction of the panel; the insert further comprises a support layer; and the stops extend from the support layer.

5. The system of claim 1, wherein: the base comprises a center support, which is configured to contact a floor, and two vertical supports; the center support extends between the two vertical supports; the vertical supports are configured to hold the frame at an elevated position above the center support; and the frame is rotatably coupled to the vertical supports.

6. The system of claim 5, wherein the base further comprises bracing, and wherein the bracing extends on only one side of the center support.

7. The system of claim 1, wherein the frame comprises a vertical centerline axis, and the frame is rotatably coupled to the base at the vertical centerline axis for vertical rotation.

8. The system of claim 7, wherein the base comprises two vertical supports and a center support extending between the vertical supports at an elevated position above a floor; and wherein the frame is rotatably coupled to the center support.

9. The system of claim 8, further comprising two or more stations disposed on a floor around the jig, wherein the frame is configured to rotate for positioning with respect to the two or more stations.

10. The system of claim 1, further comprising one or more harness element configured to removably hold the panel during construction, with the panel disposed in the frame between the insert and the harness element.

11. A method for constructing a panel for a building system, comprising: providing a jig having a frame rotatably coupled to a base; removably installing an insert within the frame of the jig, wherein the insert is configured to position components of the panel within the frame: positioning components of a first side of the panel within the frame using the insert; assembling the components to form the first side of the panel; removably securing the first side of the panel within the frame; rotating the frame of the jig; removing the insert from the frame; positioning components of a second side of the panel within the frame; and assembling the components to complete the panel.

12. The method of claim 11 , further comprising unsecuring the panel from the frame; removing the panel from the frame; and resetting the jig for construction of another substantially identical panel.

13. The method of claim 1 1 , wherein the insert comprises a plurality of stops extending from a support layer, which are configured for positioning components of the panel within the frame; and wherein positioning components of a first side of the panel within the frame using the insert comprises positioning the components atop the support layer and aligning the components using the stops of the insert.

14. The method of claim 11, wherein rotating the frame comprises horizontally rotating the frame approximately 180 degrees, and wherein rotating the frame occurs before positioning components of a second side of the panel.

15. The method of claim 14, further comprising placing the frame of the jig in a first horizontal position before positioning components of a first side of the panel within the frame using the insert, wherein rotating the frame of the jig comprises rotating the frame from the first horizontal position to a second horizontal position.

16. The method of claim 11, further comprising placing the frame of the jig in a first vertical position before positioning components of a first side of the panel, wherein rotating theframe of the jig comprises rotating the frame from the first vertical position to a second vertical position.

17. The method of claim 16, wherein rotating the frame comprises horizontally rotating the frame approximately 180 degrees.

18. A method for constructing a panel for a building system, comprising: providing a jig having a frame rotatably coupled to a base and configured for vertical rotation with respect to two or more construction stations disposed on a floor around the jig; removably installing an insert within the frame of the jig, wherein the insert is configured to position components of the panel; and installing panel components at the two or more construction stations to construct the panel.

19. The method of claim 18, wherein installing panel components at the two or more construction stations comprises: positioning components of a first station within the frame using the insert; assembling the components of the first station; rotating the frame of the jig to a second station; positioning components of the second station within the frame; assembling the components of the second station; rotating the frame of the jig to a third station; removing the insert from the frame; and positioning components of the third station within the frame; and assembling the components of the third station to complete construction of the panel.

20. The method of claim 19, further comprising releasing the panel from the frame; and resetting the jig for construction of another panel by rotating the frame back to the first station and re-installing the insert into the frame.

21. The method of claim 18, wherein both sides of the panel can be simultaneously constructed using the jig.

22. A jig for constructing a panel, comprising: a base; and a frame rotatably coupled to the base for horizontal rotation; wherein: the frame is configured to removably retain an insert which is configured to position components of the panel within the frame for construction of one of the following: an exterior wall panel, an interior wall panel, or a flooring panel;the frame comprises a centerline axis, and the frame is coupled to the base at the centerline axis; and the frame is configured for 360-degree rotation about the centerline axis.

23. The jig of claim 22, wherein: the base comprises a center support, configured to contact a floor, and two vertical supports; the center support extends between the two vertical supports; the vertical supports are configured to hold the frame at an elevated position above the center support; and the frame is rotatably coupled to the vertical supports.

24. The jig of claim 23, wherein the base further comprises bracing, and wherein the bracing extends on only one side of the center support.

25. A system for constructing a panel for component construction, comprising: a jig having a base; and an insert configured to couple to the base, wherein the insert is configured to position components of the panel, and wherein the insert is configured to removably retain the components relative to the base.

26. The system of claim 25, wherein the insert is configured for construction of one of the following: an exterior wall panel, an interior wall panel, a roof panel, or a flooring panel.

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