Workstation for manufacturing prefabricated construction panels

Abstract

The present invention relates to a workstation for manufacturing prefabricated construction panels, comprising: at least one work platform, comprising at least one upper plate; at least one perimeter frame, comprising at least two profiles arranged at a right angle, which defines an assembly boundary for the manufacture of at least one structural partition of at least one panel on the at least one upper plate; at least one vertical inner structure arranged on the at least one upper plate, within the assembly boundary, comprising at least one vertical part; and at least one horizontal inner structure arranged on the at least one upper plate, within the assembly boundary, comprising at least one horizontal part. The at least one perimeter frame, the at least one vertical inner structure and the at least one horizontal inner structure define at least one Cartesian plane, which defines at least one positioning coordinate (x, y) of at least one construction part forming the at least one structural partition of the at least one panel; and the positioning of the at least one construction part defines at least one intersection coordinate (x, y) between the at least one construction part forming the at least one structural partition of the panel, which determine the attachment position between them. The invention further relates to a method for producing a panel library for the manufacture of prefabricated panels. The invention further relates to a panel library for the manufacture of prefabricated panels. The invention further relates to a method for manufacturing prefabricated construction panels. The invention further relates to a system for manufacturing prefabricated panels. The invention further relates to a prefabricated construction panel. The invention further relates to a method for constructing a building, and to such building.

Description

[0001] A workstation for manufacturing prefabricated construction panels

[0002] DESCRIPTIVE MEMORANDUM

[0003] [1] The present invention relates to a workstation for manufacturing prefabricated construction panels, and to a manufacturing process that allows these panels to be manufactured in a nested configuration, enabling the creation of multiple architectural designs for housing construction. The workstation of the invention uses predefined assembly units, forming a standardized panel library, thereby limiting any variations in assembly time or potential assembly failures. This results in a substantial improvement in productivity and panel manufacturing quality.

[0004] [2] In this sense, the workstation of the invention essentially comprises at least one work platform, comprising at least one top plate; at least one perimeter frame, comprising at least two profiles arranged at right angles, which defines an assembly limit for the manufacture of at least one structural partition or panel on the at least one top plate; at least one vertical interior structure arranged on the at least one top plate, within the assembly limit, comprising at least one vertical piece; and at least one horizontal interior structure arranged on the at least one top plate, within the assembly limit, comprising at least one horizontal piece;where at least one perimeter frame, at least one vertical interior structure and at least one horizontal interior structure define at least one Cartesian plane, which allows defining at least one positioning coordinate (x, y) of at least one construction piece that makes up the at least one structural partition of the at least one panel; and where from the positioning of the at least one construction piece at least one intersection coordinate (x, y) is defined between the at least one construction piece that makes up the at least one structural partition of the panel, which allows determining the fixing position between them.

[0005] [3] Furthermore, the present invention also describes a panel library for the manufacture of prefabricated panels and a process for generating said library, which essentially comprises the steps of: a) selecting at least one positioning coordinate (x, y), which defines the position of at least one building piece to form at least one structural partition of at least one panel type, in at least one Cartesian plane formed on at least one upper plate of at least one work platform of the workstation; b) forming at least one group of coordinates (x, y), which comprises the at least one positioning coordinate (x, y) that make up the at least one structural partition of the at least one panel type; c) defining at least one intersection coordinate (x, y) between the at least one building piece that makes up the at least one panel type, which allows determining the fixing position between them;d) assign a reference to at least one group of coordinates (x,y) that make up at least one structural partition of at least one panel type; e) store the assigned reference in at least one storage medium; and f) repeat steps a)-e) at least once to generate additional panel types.

[0006] [4] According to another embodiment of the invention, a manufacturing process for prefabricated construction panels is further described, which essentially comprises the steps of: selecting at least one reference related to at least one group of coordinates (x,y) that make up at least one structural partition of at least one panel type from the panel library; arranging at least one construction piece in at least one positioning coordinate (x, y) on at least one upper plate of at least one work platform of the workstation, where said positioning coordinate (x, y) is defined by the at least one group of coordinates (x, y), where the assembly of the at least one panel is delimited by a perimeter frame, comprising at least two profiles arranged at a right angle, thus defining an assembly limit;fix each of the at least one construction piece, according to at least one intersection coordinate (x, y) that exists between them, defined by the at least one group of coordinates (x, y); and repeat at least once steps b)-c) to generate additional panels of the type selected in step a); or repeat at least once steps a)-c) to manufacture other panel types.;

[0007] [5] Additionally, the present invention also relates to a manufacturing system for prefabricated panels comprising essentially: at least one raw material preparation station, in which at least one building piece is prepared to manufacture at least one panel, according to at least one set of coordinates (x,y) selected from the panel library; wherein the manufacturing system further comprises at least one sequential process line, which in turn comprises: at least one workstation, in which the at least one building piece is arranged according to the at least one set of coordinates (x, y); at least one insulation and membrane station; at least one packaging station; and at least one means of storage and / or transport.

[0008] [6] Finally, the present invention also relates to a process for the construction of a building, comprising the steps of: manufacturing, in at least one prefabricated panel manufacturing system, at least one panel corresponding to the walls, windows, doors, floor and roof of the building; transporting said at least one panel to the building location; and arranging said at least one panel according to a building typology for each of the walls, windows, doors, floor and roof of said building.

[0009] [7] Based on the workstation and manufacturing process of the invention, it is possible to provide a solution adaptable to small and medium-sized industries related to panel manufacturing, which allows for the optimization of labor in the plant, reducing manufacturing times through the standardization of the assembly process.

[0010] BACKGROUND

[0011] [8] In recent decades, the construction sector has faced multiple challenges related to productivity, environmental sustainability, and the growing demand for affordable, quality housing. The use of traditional methods has led to high costs, long construction times, and a significant environmental impact due to the materials and processes used. Prefabricated housing has emerged as a promising solution, but its adoption has been limited due to problems such as a lack of standardization, dependence on skilled labor, and fragmentation in production processes.

[0012] [9] The main problem identified is the lack of efficient and standardized systems for the prefabrication of timber structures for construction, which would reduce reliance on manual processes, optimize material use, and improve productivity. This is exacerbated by the fragmentation of design and manufacturing processes, leading to production inefficiencies and high costs.

[0013]

[0010] Existing market solutions encompass a wide range of manufacturing processes, from manual manufacturing stations to highly automated production systems. However, these options present significant limitations. For example, manual systems rely heavily on operator skill, resulting in inconsistent quality and longer production times. On the other hand, automated solutions offer productivity efficiency and consistent quality, although they require substantial initial investment, limiting their accessibility for small and medium-sized enterprises. Furthermore, emerging technologies such as CAD / BIM have improved design, but their integration with manual or semi-automated manufacturing processes remains a challenge.

[0014]

[0011] In this sense, the present invention is applicable to the construction industry, specifically to the manufacturing area, for prefabricating or industrializing into units or elements (ID) that are assembled or integrated to generate panelized units or components (2D), which in turn are mounted to constitute volumetric units or modules (3D) that configure the structure of a final construction.

[0015]

[0012] In the housing construction industry there are some solutions that attempt to address this problem, as described below.

[0016]

[0013] For example, Soukup America offers a modular system called “Framer-Modular,” which is designed for the flexible production of wall panels. This system provides assembly tables that allow for the efficient manufacturing of wall panels at the customer's production site. The system's modularity facilitates its adaptation to different configurations and production needs.

[0017]

[0014] Modular Building Automation offers an automated station for constructing timber structures called the “X-Frame.” This station uses automatic positioning arms to determine the location of studs and subcomponents, assembling the panel step by step. The nail guns and positioning arms are controlled by an integrated CNC unit, which receives processing information from the drawing software via an interface, allowing programming of the panel manufacturing sequence without operator intervention.

[0018]

[0015] Finally, following the same line of thought as the previous examples, Panels Plus develops wall panel assembly equipment designed for the production of wood or steel wall panels, as well as flooring components and other framing elements. These assembly tables allow for the construction of walls of varying heights and lengths, with square stops and pneumatic clamping to ensure panel quality and consistency. Optionally, tool trolleys with automatic indexing can be included to improve assembly efficiency.

[0019]

[0016] Now, in the field of patents there are also some solutions that aim to try to solve the problem posed by the present invention.

[0020]

[0017] One of these is international patent application W02023060348A1. This application describes an automated, robotic method for assembling structural wood panels. The system uses a tenon to join segmented subpanels into a single unit. The invention addresses the need to assemble panels with high precision and efficiency, facilitating the mass production of solid wood panels with robust joints. The process enables efficient manufacturing by robots that assemble the subpanels in segmented interstitial layers, thereby improving the quality and durability of the resulting panels.

[0021]

[0018] Furthermore, US patent 5542653A discloses a portable modular assembly table for wood framing. The system consists of subassemblies that include adjustable bench modules and leg modules, facilitating the construction of wall panels of varying heights and lengths. The table is easy to disassemble and transport in a standard pickup truck, making it ideal for small contractors. It also incorporates a surface with a sliding plastic material to facilitate the removal of completed panels without the need for complex roller mechanisms.

[0022]

[0019] Finally, US patent 11851897B2 presents an automated system for manufacturing building panels. It uses CNC and robotic technologies to position and assemble structural elements, ensuring a high degree of precision in the production process. The system allows for automatic adjustment of panel dimensions and the handling of various assembly configurations, thereby optimizing the manufacturing of modular building structures. This method improves efficiency by reducing manufacturing time and minimizing human error.

[0023]

[0020] However, an analysis of each of these alternatives, whether offered by industry or described in patent documents, reveals that they all point to systems that utilize complex positioning systems for panel components, such as robotic arms or CNC technologies, thus eliminating human intervention in the process. Furthermore, none of these solutions involves a workstation with a fixed upper surface of vertical and horizontal pieces, where their position cannot be adjusted to manufacture multiple panel types from a panel library. This library would allow for the production of all the necessary wall, floor, and / or roof panels for a building, such as a house.Therefore, the workstation of the invention does not need adjustments between the manufacture of one type of panel and another, which is necessary in the examples described above, complicating and increasing the cost of said systems in order to maintain the indicated efficiency.

[0024]

[0021] In view of the above, it is evident that there is a need for a technological solution that addresses the shortcomings of state-of-the-art solutions, since none of them address the problem from prefabrication to industrialization in a plant for manual or semi-automatic processing, which will contribute to prefabricating parts, pieces and components (housing panels) designed in a standardized way, facilitating the architectural process of determining which and how many panels will be used.

[0025]

[0022] In this regard, the present invention introduces a nested manufacturing workstation that enables the creation of standardized prefabricated panels, overcoming the limitations identified in the prior art. Key advantages include:

[0026] 1) Optimization of the assembly process through nested configurations that reduce production time and errors.

[0027] 2) Reduction of production costs by minimizing material waste and dependence on advanced technology.

[0028] 3) Greater accessibility for small and medium-sized enterprises thanks to a modular and scalable design.

[0029] 4) Compatibility with digital tools such as CAD / BIM, allowing seamless integration between design and manufacturing.

[0030] 5) Environmental sustainability through the efficient use of certified wood and the reduction of the carbon footprint in production processes.

[0031]

[0023] This and other advantages associated with other aspects of the technology are described in more detail below.

[0032] DESCRIPTION OF THE INVENTION

[0024] The invention relates to a workstation for manufacturing prefabricated construction panels and to a manufacturing process for prefabricated construction panels, which allows the manufacture of a series of panels in a “nested form”, providing a substantial improvement in productivity and quality of panel making.

[0033]

[0025] According to a first preferred embodiment of the invention, the workstation comprises:

[0034] - at least one work platform, comprising at least one top plate;

[0035] - at least one perimeter frame, comprising at least two profiles arranged at right angles, which defines an assembly limit for the manufacture of at least one structural partition of a panel on the at least one top plate;

[0036] - at least one internal vertical structure arranged on the at least one upper plate, within the assembly limit, comprising at least one vertical piece; and

[0037] - at least one horizontal internal structure arranged in the at least one upper plate, within the assembly limit, comprising at least one horizontal piece; wherein the at least one perimeter frame, the at least one vertical internal structure and the at least one horizontal internal structure define at least one Cartesian plane, which allows defining at least one positioning coordinate (x, y) of at least one construction piece that makes up the at least one structural partition of the at least one panel; and wherein from the positioning of the at least one construction piece at least one intersection coordinate (x, y) is defined between the at least one construction piece that makes up the at least one structural partition of the panel, which allows determining the fixing position between them.

[0038]

[0026] From the workstation of the invention, it is possible to manufacture multiple types of structural panel partitions, such as walls, windows, or doors, without needing to change the configuration of the structural elements arranged on the work platform (perimeter frame, vertical interior structure, horizontal interior structure). This allows for increased assembly speed in small industries, where the manufacture of each panel assembly is carried out entirely manually by one or more workers. Thanks to the workstation of the invention, a standardized manufacturing process is achieved, raising quality standards.

[0027] According to another embodiment of the invention, each of the at least one vertical piece and each of the at least one horizontal piece are arranged at a uniform distance from adjacent pieces, respectively.

[0039]

[0028] According to another embodiment of the invention, each of the at least one vertical piece and the at least one horizontal piece are arranged at a variable distance between adjacent pieces, respectively.

[0040]

[0029] According to another embodiment of the invention, the at least one work platform is manufactured from at least five profiles.

[0041]

[0030] According to another embodiment of the invention, the at least five profiles are made of at least one of wood, metal, polymer, or a combination thereof.

[0042]

[0031] According to another embodiment of the invention, the at least one top plate is made of at least one wood, metal, polymer, or a combination thereof.

[0043]

[0032] According to another embodiment of the invention, the workstation further comprises at least one mechanical positioning element, arranged on the at least one top plate and at an angle with respect to each of the at least two profiles of the at least one perimeter frame, and with each of the at least one vertical piece and the at least one horizontal piece.

[0044]

[0033] According to another embodiment of the invention, the at least one mechanical location element comprises at least one perforation for fixing to the surface of the at least one upper structure.

[0045]

[0034] According to another embodiment of the invention, the at least one mechanical locating element is made of at least one wood, metal, polymer, or a combination thereof.

[0046]

[0035] Preferably, the at least one mechanical element corresponds to a plate or bracket, which is arranged at an angle to each of the at least two profiles of the at least one perimeter frame, and to each of the at least one vertical piece and the at least one horizontal piece.

[0047]

[0036] According to another embodiment of the invention, the at least two profiles of the at least one perimeter frame, the at least one vertical piece, and the at least one horizontal piece are manufactured from at least one of wood, metal, polymer, or a combination thereof.

[0037] According to another embodiment of the invention, the fastening between the at least one construction piece is carried out by means of at least one pneumatic nailing, mechanical nailing, or a combination thereof.

[0048]

[0038] According to a second embodiment of the invention, a process is described for generating a panel library for the manufacture of prefabricated panels according to the workstation of the previous embodiment, comprising the steps of: a) selecting at least one positioning coordinate (x, y), which defines the position of at least one building piece to form at least one structural partition of at least one panel type, in at least one Cartesian plane formed on at least one upper plate of at least one work platform of the workstation; b) forming at least one group of coordinates (x, y), which comprises the at least one positioning coordinate (x, y) that make up the at least one structural partition of the at least one panel type;c) define at least one intersection coordinate (x, y) between the at least one construction piece that makes up the at least one panel type, which allows determining the fixing position between them; d) assign a reference to the at least one group of coordinates (x,y) that make up the at least one structural partition of the at least one panel type; e) store the assigned reference in at least one storage medium; and f) repeat steps a)-e) at least once to generate additional panel types.

[0049]

[0039] According to a third embodiment of the invention, a panel library for the manufacture of prefabricated panels is described, which is generated through the process of the second embodiment.

[0050]

[0040] The panel library of the invention allows for the storage of different types of structural panel partitions, so that the worker(s) in charge of operating the workstation can obtain the necessary information regarding the arrangement of each of the construction pieces, generally made of wood. In this way, the worker only needs to arrange each of the construction pieces as if assembling a building block set. Similarly, those in charge of preparing the raw materials can obtain all the necessary information from the panel library, such as the quantity of construction pieces and their dimensions, so as to provide those in charge of the workstation with the exact quantity of pieces for their subsequent arrangement on the workstation and their fixing or joining by means of pneumatic nailing, for example.

[0051]

[0041] In this sense, there can be multiple panel libraries, depending on the type of panel to be manufactured. For example, there could be panel libraries for walls, windows, and doors, other libraries for floors, and other libraries exclusively for roofs or ceilings, depending on the construction needs.

[0052]

[0042] Preferably, the at least one storage medium corresponds to at least one of a data cloud, a laptop computer, a tablet, a smartphone, a writing medium such as a notebook, etc.

[0053]

[0043] According to a fourth embodiment of the invention, a manufacturing process for prefabricated construction panels is described, according to the workstation of the first embodiment of the invention and the panel library of the third embodiment of the invention, comprising the steps of: a) selecting at least one reference related to at least one group of coordinates (x,y) that make up at least one structural partition of at least one panel type from the panel library;b) placing at least one construction piece at at least one positioning coordinate (x, y) on at least one top plate of at least one work platform of the workstation, where said positioning coordinate (x, y) is defined by at least one group of coordinates (x, y), where the assembly of at least one panel is delimited by a perimeter frame, comprising at least two profiles arranged at right angles, thus defining an assembly limit; c) fixing each of the at least one construction piece, according to at least one intersection coordinate (x, y) that exists between them, defined by at least one group of coordinates (x, y); and d) repeating steps b)-c) at least once to generate additional panels of the type selected in step a);e) repeat steps a)-c) at least once to manufacture other panel types.

[0044] The invention process makes it possible to standardize the manufacture of prefabricated panel partitions by using a single workstation that does not require modification of the elements arranged on its upper platform. This is achieved through the use of a panel library comprising a plurality of structural panel partition types that can be manufactured at that station. This allows for increased process productivity and reduced manufacturing errors without the need for advanced technology such as CNC or robotic arms, which is not accessible to small or medium-sized industries.

[0054]

[0045] Preferably, the fixing or nailing process is carried out from vertical pieces (uprights) to horizontal pieces (top and bottom plates) to fix the structure or partition of the panel.

[0055]

[0046] According to another embodiment of the invention, the process further comprises fixing at least one structural plate to the structure of at least one panel by means of at least one fastener. Preferably, the fixing or nailing of the at least one structural plate to the structure or partition of the panel is carried out by means of fasteners with a pneumatic process.

[0056]

[0047] According to another embodiment of the invention, the process further comprises preparing raw material, according to at least one set of coordinates (x,y) that make up at least one structural partition of at least one panel from the panel library.

[0057]

[0048] Preferably, the preparation of the raw material is divided into: wood chopping, and cutting of structural plates for openings in doors and / or features in windows.

[0058]

[0049] According to another embodiment of the invention, the process further comprises turning over at least one braced panel at the same workstation or at a subsequent workstation arranged thereafter.

[0059]

[0050] According to another embodiment of the invention, the process further comprises installing at least one means of thermal insulation in at least one interior zone of at least one panel.

[0060]

[0051] According to another embodiment of the invention, the process further comprises closing at least one panel through a water-repellent or specialized vapor barrier membrane.

[0061]

[0052] According to another embodiment of the invention, the process further comprises attaching at least one adhesive means to seal the junctions of the waterproof membrane to the structure of at least one panel in order to reduce airflow within said structure, achieving a first stage of airtightness required in the panelized state. Preferably, the at least one adhesive means is an adhesive tape.

[0062]

[0053] According to another embodiment of the invention, the process also includes performing a quality control protocol on at least one panel before it is packed and stacked for transport or storage in a warehouse.

[0063]

[0054] According to a fifth embodiment of the invention, a manufacturing system for prefabricated panels is described, according to the workstation of the first embodiment of the invention, and according to the panel library of the third embodiment of the invention, comprising: a) at least one raw material preparation station, in which at least one construction piece is prepared to manufacture at least one panel, according to at least one set of coordinates (x,y) selected from the panel library; wherein the manufacturing system further comprises at least one sequential process line, which in turn comprises: b) at least one workstation, in which the at least one construction piece is arranged according to the at least one set of coordinates (x,y); c) at least one insulation and membrane station; d) at least one packaging station; and e) at least one means of storage and / or transport.

[0064]

[0055] From the manufacturing system of the invention, it is possible to carry out the complete process of manufacturing panels for construction, for which only one workstation is needed to build multiple types of panels according to the panel library used.

[0065]

[0056] According to another embodiment of the invention, the at least one insulation and membrane station and the at least one packaging station are mobile.

[0066]

[0057] Additionally, according to a sixth embodiment of the invention, a prefabricated panel for construction is described, which is manufactured according to the manufacturing process of the fourth embodiment of the invention.

[0067]

[0058] Furthermore, according to a seventh embodiment of the invention, a process for the construction of a building is described, comprising the steps of: a) manufacturing, in at least one prefabricated panel manufacturing system according to the fifth embodiment of the invention, at least one panel corresponding to the walls, windows, doors, floor and roof of the building; b) transporting said at least one panel to the building location; and c) arranging said at least one panel according to a building typology for each of the walls, windows, doors, floor and roof of said building.

[0068]

[0059] According to another embodiment of the invention, the at least one prefabricated panel manufacturing system comprises at least one sequential process line for each of the following panel types: i) walls, windows and doors; ii) floor; and iii) roof.

[0069]

[0060] In this regard, it is important to emphasize once again the relevance of the workstation in the described construction process, since from a single station it is possible to manufacture all the panels necessary to form the walls, doors, and windows of the building. Similarly, additional workstations can be used to manufacture all the panels necessary to form the floor and roof of the building, according to a specific building typology.

[0070]

[0061] This is a very important advantage, since from a single panel library containing different panel types, it is possible to manufacture all the panels of a given type (walls, doors, windows, floors, roof) for a building. Therefore, for the construction of a building, only one panel library for each group of panels required (one for walls, doors, and windows; another for floors; and another for the roof) would be needed, along with three workstations dedicated to each of these panel groups. In this way, it is possible to standardize the construction of buildings, such as houses, by enabling the creation of different types from the panel libraries, ultimately optimizing and streamlining the construction process.

[0071]

[0062] Finally, according to an eighth embodiment of the invention, a building is described, which is constructed using the process for constructing the seventh embodiment of the invention.

[0063] From the above, it is possible to observe that the present invention breaks the paradigm that industrialization is not possible in a factory, allowing for the prefabrication of parts, pieces, and components (housing panels) designed in a standardized manner, leaving it to the architect to determine which and how many panels will be used. This allows for improved labor productivity, a reduced carbon footprint, and a lower level of waste, which has been a global challenge in the struggle to incorporate industrialization into processes.

[0072] BRIEF DESCRIPTION OF THE FIGURES

[0073]

[0064] As part of the present invention, the following representative figures are presented, which show preferred configurations of the invention and, therefore, should not be considered as limiting the definition of the claimed subject matter.

[0074] Figures 1 to 2 show a workstation for manufacturing prefabricated construction panels, according to a preferred embodiment of the invention for wall panels, doors and windows;

[0075] Figures 3 to 4 show a workstation where vertical and horizontal pieces have been superimposed to manufacture prefabricated panels for construction, according to a preferred embodiment of the invention for floor and roof;

[0076] Figure 5 shows a Cartesian plane with a series of coordinates (x, y), formed on the workstation, to form at least one structural partition of at least one panel, according to a preferred embodiment of the invention;

[0077] Figure 6 shows a panel library, according to a preferred embodiment of the invention.

[0078] Figures 7 to 26 show each of the structural partitions that can be made, according to the panel library in Figure 6;

[0079] Figures 27 and 28 show a manufacturing system for prefabricated panels, according to preferred embodiments of the invention; and

[0080] Figure 29 shows different types of buildings that can be carried out from the workstation, according to preferred modalities of the invention.

[0081] DETAILED DESCRIPTION OF THE FIGURES AND OF AN EXEMPLARY MODALITY

[0065] With reference to the accompanying figures, Figures 1 to 2 show the workstation (1) according to the first modality of the invention for the manufacture of structural partitions of panels for walls, doors and windows of a building, which corresponds to a table or work platform (10), constituted, in an exemplary manner, by an upper structure with dimensions of 2,500 mm x 2,500 mm, which can be manufactured in wood or metal and made from 5 pieces, preferably 5 beams of 50 mm x 100 mm in wood, or preferably 5 square profiles of 50 mm x 50 mm in metal, raised 800 mm from the floor by four legs of the same dimensions in wood (50 mm x 100 mm) or metal (50 mm x 50 mm).On the structure of the table or work platform (10) at least one top plate (11), preferably two top plates (11) arranged contiguously, made from plywood measuring 1,220 mm x 2,440 mm, and with a thickness of 18 mm, is fixed to reinforce the structure and uniform the work area that will be arranged to install the nested fixing design to perform multi-manufacturing of panels.

[0082] Application

[0083]

[0066] To provide the workstation (1) with the functionality to assemble and manufacture multiple panels on the table or platform defined in the previous section, 3 types of components are established by their location, according to what can be observed in Figures 1 to 2: a) Perimeter frame of 4 equal sides; b) Vertical interior structure of minimum 3 and maximum 5 vertical pieces (12) of equal squareness; c) Horizontal interior structure of minimum 4 and maximum 8 positions for horizontal pieces (13) of variable length of equal squareness.

[0084]

[0067] These types of components require a fixed position depending on the design of the panel to be manufactured, being fixed to the top plates (11) through mechanical positioning elements.

[0085] Mechanical location elements

[0086]

[0068] Angled metal plates (20 mm to 40 mm) are prepared, cut into 200 mm lengths with two holes in the base for fixing with wood screws. Components by location - Perimeter frame

[0087]

[0069] Two metal angle brackets are fixed to this table or platform, defining the external position or assembly limits on the four sides or edges near the 90° vertices, with external dimensions for a base panel of 2440 mm x 2440 mm. This establishes the location of four pieces (two flat bars (horizontal position) and two uprights (vertical position)) that constitute the fixed perimeter for forming the frame of a future prefabricated panel. Once the four pieces are positioned, they can be fixed using pneumatic nailing or mechanical fasteners (screws).

[0088] Components by location - Vertical interior structure

[0089]

[0070] For the multiple panels to be manufactured, fixed positions are defined for the vertical pieces (12) separated in multiples of 305 mm, measured in both directions (left to right) from any vertex where the points are established: 0 mm; 305 mm; 610 mm; 1220 mm; 1830 mm; 2440 mm.

[0090]

[0071] Once the points on the axis of the vertical piece (12) have been defined, metal angles are set at both ends (start and end) of the length of the piece.

[0091]

[0072] It should be noted that the location of doors and windows coincides with the defined multiple measurements in the horizontal structure, standardizing their position and structure within the panel to be prefabricated. It should also be noted that a minimum distance of 305 mm is defined from the left or right edge to the vertical perimeter of the panel.

[0092]

[0073] According to Figure 1, the vertical interior structure for a workstation (1) for the manufacture of wall panels, doors and / or windows can be observed.

[0093]

[0074] Similarly, in Figure 3, the arrangement of the vertical interior structure for the manufacture of floor panels (in fuchsia), roof (in black) and for the pediment (in green) of a building can be seen, with its corresponding vertical floor pieces (12a), vertical roof pieces (12b) and vertical pediment pieces (12c).

[0094] Components by location - Horizontal interior structure

[0075] For the multiple panels to be manufactured, fixed positions are defined for the horizontal pieces (13) separated into four sections for the windows and 1 section for the doors.

[0095]

[0076] Once the points on the axis of the horizontal piece have been defined, metal mechanical location elements are placed at both ends (start and end) of the length of the piece, located between vertical pieces (12) where they will be fixed by the action of a mechanical or pneumatic tool.

[0096]

[0077] It should be noted that the placement of doors and windows follows a left or right symmetry, with the vertical structure coinciding with the defined multiples of measurements, thus standardizing their position and structure within the prefabricated panel. It should also be noted that a maximum height of 2220 mm (door lintel height / window feature height) is defined for placement.

[0097]

[0078] According to Figure 2, the horizontal interior structure for a workstation for the manufacture of wall panels, doors and / or windows can be observed.

[0098]

[0079] Similarly, in Figure 4, the arrangement of the horizontal interior structure for the manufacture of floor panels (in fuchsia), roof (in black) and for the pediment (in green) of a building can be seen, with its corresponding horizontal floor pieces (13a), horizontal roof pieces (13b) and horizontal pediment pieces (13c).

[0099] Panel Library

[0100]

[0080] The innovation that defines the design of structural elements expressed in a nested panel library that allows the manufacture of “n” panels on the same manufacturing table or platform is explained below.

[0101]

[0081] For the purpose of designing an exemplary library, a process of creation and iteration was carried out under an applied research model, from model M00 to model MI 9, performing a physical verification one by one with the base matrix (MXX). The entry criteria are detailed below:

[0102] 1) Panel dimensions (2440 mm x 2440 mm)

[0103] 2) Distance between uprights to the axle (7) = (0; 305; 610; 1220; 1830; 2135; 2440 mm)

[0104] 3) Proportion in doors / windows = use left or right frame ONLY on point 2 studs 4) Symmetry in doors / windows = use "mirror" design to give balance, considering that door openings and window features ALWAYS use point 2 studs.

[0105] 5) Lower / upper distance between door / window = use standard measurements of 2220 mm (door lintel height / window feature height)

[0106] 6) Left / right width of door / window panel = use standard measurement with margins between 305 mm and 2220 mm.

[0107]

[0082] MXX should be considered as the base matrix for constructing all the intersection combinations between axes (x, y), where it is plotted on a Cartesian plane as a metric for locating horizontal and vertical pieces. These intersections allow for locating the fixing position between pieces (pneumatic nailing). Figure 5 shows the base matrix where letters are defined for each location, according to the resulting Cartesian coordinate plane (x, y).

[0108]

[0083] In this way, the arrangement of the construction pieces on the workstation is carried out as follows:

[0109] Bottom sill: A, B, C, D, E, F, G

[0110] Top sill: AA, BB, CC, DD, EE, FF, GG

[0111] - Perimeter uprights: A-AA, G-GG

[0112] Right inside feet: B-BB, C-CC, D-DD, E-EE, F-FF,

[0113] - Interior pieces: V, W, X, Y, Z / Q, R, S, T, U / M, N, Ñ, O, P / H, I, J, K, L

[0114]

[0084] In this regard, Figure 6 shows a panel library with 20 different types for manufacturing structural partitions, corresponding to the walls, doors, and windows of a building. Based on the methodology described above, it is also possible to create panel libraries for other groups of building panels, such as floors and roofs.

[0115]

[0085] The description of each type of structural panel partitions in Figure 6 is described below:

[0116] - M00: Blind wall

[0117] M01-M02: Gate

[0118] M03-M04: Door and window

[0119] M05-M19: Window

[0086] Similarly, Figures 7 to 26 show the arrangement of the building pieces on the workstation, according to the panel typologies described in Figure 6.

[0120] Process and manufacturing system for prefabricated panels

[0121]

[0087] Figures 27 and 28 show the arrangement of two exemplary modes for the panel manufacturing system (100) described by the present invention, in which different stations are arranged that perform the necessary tasks for the manufacture of prefabricated panels.

[0122]

[0088] In Figure 27, a first raw material preparation station (110) is shown, which supplies construction pieces, cut according to the panel type(s) to be manufactured according to the panel library, to three sequential process lines (120), which in turn comprise each one a work station (121) according to the first modality of the invention, an insulation and membrane station (122) and a packaging station (123), to finally send the panels to a storage means, such as a warehouse (140) or to a means of transport, such as a truck (130) for shipment to the work site.

[0123]

[0089] In this way, it is possible to have a sequential process line for the manufacture of wall panels, doors and windows, according to a first panel library associated with a first workstation, a second sequential process line for the manufacture of floor panels, according to a second panel library associated with a second workstation, and a third sequential process line for the manufacture of roof or ceiling panels, according to a third panel library associated with a third workstation.

[0124]

[0090] On the other hand, Figure 28 shows a panel manufacturing system configured in the same way as that in Figure 27, but with an additional sequential process line for panel manufacturing, which allows us to see that there is no limit to the number of process lines that a system can have, which only depends on the number of panels per unit of time that you want to manufacture.

[0125] Process for the construction of a building

[0091] Finally, in Figure 29, different building typologies are observed, specifically residential dwellings, which can be built from the panel library and the workstation of the invention.

[0126]

[0092] In this way, from the workstation and the panel library of the invention, it is possible to manufacture all the panels necessary to form a building of a particular typology, where multiple typologies can be made according to the needs of the user.

[0127]

[0093] For the examples shown in Figure 29, the panel breakdown is as follows (only the panels corresponding to walls, windows and doors are shown, however, as mentioned above, it is also possible to manufacture floor and roof panels from panel libraries that comprise the corresponding typologies):

[0128] NUMERICAL REFERENCES

[0129] 1 Workstation

[0130] 10 Work platform 11 Top plate

[0131] 12 Vertical piece

[0132] 12a Vertical floor piece

[0133] 12b Vertical cover piece

[0134] 12c Vertical pediment piece

[0135] 13 Horizontal piece

[0136] 13a Horizontal floor piece

[0137] 13b Horizontal cover piece

[0138] 13c Horizontal pediment piece

[0139] 100 Panel manufacturing system

[0140] 110 Raw material preparation station

[0141] 120 Sequential process line

[0142] 121 Workstation

[0143] 122 Insulation and membrane station

[0144] 123 Packing Station

[0145] 130 Means of transport

[0146] 140 Storage medium

[0147] Building typology type A

[0148] B Building typology type B

[0149] C Building typology type C

Claims

KING VINDIC ACTION S 1. A workstation for manufacturing prefabricated construction panels, CHARACTERIZED in that it comprises: at least one work platform, comprising at least one top plate; at least one perimeter frame, comprising at least two profiles arranged at right angles, which defines an assembly boundary for the manufacture of at least one structural partition of a panel on the at least one top plate; at least one vertical interior structure arranged on the at least one top plate, within the assembly boundary, comprising at least one vertical piece; and at least one horizontal interior structure arranged on the at least one top plate, within the assembly boundary, comprising at least one horizontal piece;where at least one perimeter frame, at least one vertical interior structure and at least one horizontal interior structure define at least one Cartesian plane, which allows defining at least one positioning coordinate (x, y) of at least one construction piece that makes up the at least one structural partition of the at least one panel; and where from the positioning of the at least one construction piece at least one intersection coordinate (x, y) is defined between the at least one construction piece that makes up the at least one structural partition of the panel, which allows determining the fixing position between them.

2. The workstation according to claim 1, CHARACTERIZED in that each of the at least one vertical piece and the at least one horizontal piece are arranged at a uniform distance between adjacent pieces, respectively.

3. The workstation according to claim 1, CHARACTERIZED in that each of the at least one vertical piece and the at least one horizontal piece are arranged at a variable distance between adjacent pieces, respectively.

4. The workstation according to any of claims 1 to 3, CHARACTERIZED in that the at least one work platform is manufactured from at least five profiles.

5. The workstation according to claim 4, CHARACTERIZED in that the at least five profiles are made of at least one of wood, metal, polymer, or a combination thereof.

6. The workstation according to any of claims 1 to 5, CHARACTERIZED in that the at least one top plate is made of at least one of wood, metal, polymer, or a combination thereof.

7. The workstation according to any of claims 1 to 6, CHARACTERIZED in that it further comprises at least one mechanical positioning element, arranged on the at least one top plate and at an angle with respect to each of the at least two profiles of the at least one perimeter frame, and with each of the at least one vertical piece and the at least one horizontal piece.

8. The workstation according to claim 7, CHARACTERIZED in that the at least one mechanical location element comprises at least one perforation for fixing to the surface of the at least one upper structure.

9. The workstation according to any of claims 7 to 8, CHARACTERIZED in that the at least one mechanical location element is made of at least one of wood, metal, polymer, or a combination thereof.

10. The workstation according to any of claims 1 to 9, CHARACTERIZED in that the at least two profiles of the at least one perimeter frame, the at least one vertical piece and the at least one horizontal piece are made of at least one of wood, metal, polymer, or a combination thereof.

11. The workstation according to any of claims 1 to 10, CHARACTERIZED in that the fastening between the at least one construction piece is carried out by at least one pneumatic nailing, mechanical nailing, or a combination thereof.

12. A process for generating a panel library for the manufacture of prefabricated panels according to the workstation of claims 1 to 11, CHARACTERIZED in that it comprises the steps of: a) selecting at least one positioning coordinate (x, y), which defines the position of at least one building piece to form at least one structural partition of at least one panel type, in at least one Cartesian plane formed on at least one upper plate of at least one work platform of the workstation; b) forming at least one group of coordinates (x, y), which comprises the at least one positioning coordinate (x, y) that forms the at least one structural partition of the at least one panel type; c) defining at least one intersection coordinate (x, y) between the at least one building piece that forms the at least one panel type, which allows determining the fixing position between them;d) assign a reference to at least one group of coordinates (x,y) that make up at least one structural partition of at least one panel type; e) store the assigned reference in at least one storage medium; and f) repeat steps a)-e) at least once to generate additional panel types.

13. A panel library for the manufacture of prefabricated panels, CHARACTERIZED in that it is generated through the process of claim 12.

14. A manufacturing process for prefabricated construction panels according to the workstation of claims 1 to 11 and the panel library of claim 13, CHARACTERIZED in that it comprises the steps of: a) select at least one reference related to at least one group of coordinates (x,y) that make up at least one structural partition of at least one panel type from the panel library; b) place at least one construction piece in at least one positioning coordinate (x, y) on at least one top plate of at least one work platform of the workstation, where said positioning coordinate (x, y) is defined by the at least one group of coordinates (x, y), where the assembly of the at least one panel is delimited by a perimeter frame, comprising at least two profiles arranged at a right angle, thus defining an assembly limit; c) fix each of the at least one construction piece, according to at least one intersection coordinate (x, y) that exists between them, defined by the at least one group of coordinates (x, y);(d) repeat steps b)-c) at least once to generate additional panels of the type selected in step a); (e) repeat steps a)-c) at least once to manufacture other types of panels.

15. The manufacturing process of claim 14, CHARACTERIZED in that it further comprises fixing at least one structural plate to the structure of the at least one panel by means of at least one fixing.

16. The manufacturing process of any of claims 14 to 15, CHARACTERIZED in that it further comprises preparing raw material, according to at least one set of coordinates (x,y) that make up at least one structural partition of at least one panel from the panel library.

17. The manufacturing process of any of claims 14 to 16, CHARACTERIZED in that it further comprises turning over the at least one braced panel at the same workstation or at a subsequent workstation arranged thereafter.

18. The manufacturing process of any of claims 14 to 17, CHARACTERIZED in that it further comprises installing at least one thermal insulation means in at least one interior zone of the at least one panel.

19. The manufacturing process of claim 18, CHARACTERIZED in that it further comprises closing at least one panel through a water-repellent or specialized vapor barrier membrane.

20. The manufacturing process of claim 19, CHARACTERIZED in that it further comprises fixing at least one adhesive means to seal water-repellent membrane joints to the structure of at least one panel to reduce airflow within said structure, achieving a first stage of required airtightness in the panelized state.

21. The manufacturing process of any of claims 14 to 20, CHARACTERIZED in that it further comprises performing a quality control protocol on at least one panel before it is packed and stacked for transport or storage in a warehouse.

22. A manufacturing system for prefabricated panels according to the workstation of claims 1 to 11 and the panel library of claim 13, CHARACTERIZED in that it comprises: a) at least one raw material preparation station, in which at least one building part is prepared to manufacture at least one panel, according to at least one set of coordinates (x,y) selected from the panel library; wherein the manufacturing system further comprises at least one sequential process line, which in turn comprises: b) at least one workstation, in which the at least one building part is arranged according to the at least one set of coordinates (x, y); c) at least one insulation and membrane station; d) at least one packaging station; and e) at least one storage and / or transport means.

23. The manufacturing system of claim 22, CHARACTERIZED in that the at least one insulation and membrane station and the at least one packaging station are mobile.

24. A prefabricated panel for construction, CHARACTERIZED in that it is manufactured according to the manufacturing process of claims 14 to 21.

25. A process for constructing a building, CHARACTERIZED in that it comprises the steps of: a) manufacturing, in at least one prefabricated panel manufacturing system according to claims 22 to 23, at least one panel corresponding to the walls, windows, doors, floor and roof of the building; b) transporting said at least one panel to the building location; and c) arranging said at least one panel according to a building typology for each of the walls, windows, doors, floor and roof of said building.

26. The process of claim 25, CHARACTERIZED in that the at least one prefabricated panel manufacturing system comprises at least one sequential process line for each of the following panel types: i) walls, windows and doors; ii) floor; and iii) roof.

27. A building, CHARACTERIZED in that it is constructed from the process for the construction of claims 25 to 26.

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