PREFABRICATED STRUCTURAL BUILDING FRAME AND METHOD OF MAKING THE SAME
First Claim
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1. A prefabricated building frame characterised by:
- structural frame elements;
expanded polystyrene foam moulded between said structural elements, said foam extending to a depth greater than said structural elements on at least one side of the frame to thereby form a foam facade; and
a coating applied to said foam facade.
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Accused Products
Abstract
The present invention relates to prefabricated structural building frames and, in particular, to foam-filled exterior wall frames for a building structure such as a house. In a preferred embodiment, each wall frame includes a foam facade on one side of the frame for receiving a finishing material and service cut-outs on the opposed internal side of the frame. The present invention also relates to a method of manufacturing the frames in accordance with building design data.
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Citations
28 Claims
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1. A prefabricated building frame characterised by:
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structural frame elements; expanded polystyrene foam moulded between said structural elements, said foam extending to a depth greater than said structural elements on at least one side of the frame to thereby form a foam facade; and a coating applied to said foam facade. - View Dependent Claims (2, 3, 4, 5, 6, 12)
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7. A prefabricated frame for a building structure such as a house, said frame characterised by:
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structural frame elements including a plurality of horizontal beams and vertical studs each having web and flange portions, said frame elements including apertures extending through said web portions at predefined locations to accommodate services, such as electrical wiring; a high density, insulating filler material moulded between said frame elements, said filler material including service cut-outs on one side of the frame which define a path for said services. - View Dependent Claims (8, 9, 10, 11)
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13. A method of producing a finished wall frame for a building structure characterised by the steps of:
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assembling a plurality of structural elements to form a wall frame; filling said frame with expanded polystyrene foam to a depth greater than that of the structural elements on one side of the wall frame, to thereby form a foam facade having no exposed metallic surface; applying a weatherproof finishing material to said foam facade such that said facade is suitable as an external surface of said building structure. - View Dependent Claims (14, 27, 28)
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15. A method of producing prefabricated frames for a building structure such as a house, including the steps of:
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inputting data relating to a design of the structure into a computer program which translates the design data into designs of a plurality of separate frames that have the correct size and shape to be assembled together to complete the structure, and produce operational instructions for roll-forming strip and cutting the roll-formed strip into structural elements; roll-forming and cutting the strip in accordance with said operational instructions; assembling the frames; filling the frames with a high density insulating material, such as expanded polystyrene foam to a depth greater than the structural elements on at least one side of each frame to thereby form a metal-free foam facade; and applying a weatherproof coating to said foam facade. - View Dependent Claims (16, 17, 18, 19)
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20. A method of producing prefabricated frames for a building structure such as a house, including the steps of:
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inputting data relating to a design of the structure into a computer program which translates the design data into designs of a plurality of separate frames that have the correct size and shape to be assembled together to complete the structure, and produce operational instructions for roll-forming strip, cutting the roll-formed strip into structural elements, and cutting service apertures in the structural elements; roll-forming, cutting and providing service apertures in the strip in accordance with said operational instructions; assembling the frames; and filling the frames with a high density insulating material, such as expanded polystyrene foam. - View Dependent Claims (21, 22, 23, 24, 25)
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26. A method of manufacturing a prefabricated wall frame for a house including the steps of:
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inputting data relating to a design of the house into a computer program which translates the design data into designs of a plurality of separate wall frames that have the correct size and shape to be assembled together to complete the building of the house, and produce operational instructions for roll-forming strip and cutting the roll-formed strip into structural elements, cutting service apertures in the structural elements, cutting service channels into the frame, filling the frame with expanded polystyrene foam, applying an additional layer of foam and a coating material; roll-forming, cutting and providing service apertures in the strip in accordance with said operational instructions to form the structural elements forming part of each frame; assembling the frames; filling the frames with expanded polystyrene foam in accordance with said operational instructions; cutting service channels into the foam in accordance with said operational instructions; applying an additional layer of foam to one side of frames which are identified as being external wall frames of the house in accordance with the operational instructions to thereby form a smooth external facade; and applying said coating material to the external facade in accordance with the operational instructions.
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Specification