Manufacturing method for a prefabricated building panel

• US 20070271870A1
• Filed: 02/16/2007
• Published: 11/29/2007
• Est. Priority Date: 04/14/2006
• Status: Abandoned Application

• Current Assignee: Genesistp, Inc.
• Original Assignee: Genesistp, Inc.
• Inventors: Tancredi, Michele, Churchill, Michael, Aprile, Giuseppe, Mifsud, Vincent
• Application Number:
  US11/707,561
• Publication Number:
  US 20070271870A1
• Time in Patent Office: Days
• US Class Current: 52/745.200
• CPC Class Codes: B21F 27/128 of three-dimensional form by connecting wire networks, e.g. by projecting wires through an insulating layer
• CPC Class Codes: B23P 19/04 for assembling or disassembling parts
• CPC Class Codes: B23P 21/004 the units passing two or more work-stations whilst being composed

Abstract

The disclosed technology enables manufacturers to efficiently design and manufacture structural wall panels, floor panels and roof panels from cold-formed steel for use in residential and commercial construction. The panels are individual components that can be installed at a building site to form a structure that includes walls, floor and a roof. Structures may be manufactured in a manufacturing facility and delivered to a construction site for installation.

Claims

1-124. -124. (canceled)

125. A method of manufacturing a metal frame building panel for use in building construction, the method comprising the steps of:

selecting components for an individual building panel;

placing the components on a material transport system;

transporting the components on the material transport system to a framing table;

assembling the components into an assembled panel on the framing table; and

removing the assembled panel from framing table.

126. The method of claim 125, further comprising the steps of:

placing the assembled panel onto at least one bi-directional roller table;

transporting the assembled panel on the at least one bi-directional roller table to at least one post-assembly work station; and

performing post-assembly work on the assembled panel to complete the panel.

127. The method of claim 126, wherein the one or more post-assembly work station comprises at least one of a welding station, a sheeting table, a painting station, an insulation insertion station, and combinations thereof.

128. The method of claim 126, further comprising the steps of:

lifting the completed panel using an overhead gantry; and

moving the completed panel to a storage area using the overhead gantry.

129. The method of claim 125, wherein the material transport system comprises at least one work station.

130. The method of claim 129, wherein the at least one work station comprises at least one of a tray loading station, an inventory check station, a test station, a monitoring station, a pre-weld station, a sub-assembly station, an assembly station, a post-weld station, and a sheeting station.

131. The method of claim 125, wherein the assembling step comprises:

positioning the components in a predetermined arrangement; and

pinning the components together to form the assembled panel.

132. The method of claim 131, wherein the pinning step is at least partially automated.

133. The method of claim 125, wherein at least one of the steps is at least partially automated.