Prefabricated structural building frame and method of making the same
First Claim
Patent Images
1. A method of producing prefabricated frames for a building, including the steps of:
- inputting data relating to a design of the building into a computer program;
automatically translating the data into designs of a plurality of separate frames, the plurality of separate frames comprising a plurality of structural elements and having a size and shape to be assembled together to complete the building;
automatically producing operational instructions for roll-forming machinery and cutting machinery to fabricate the plurality of structural elements;
roll-forming a strip with the roll-forming machinery;
cutting the strip with the cutting machinery into the plurality of structural elements;
wherein the steps of roll-forming and cutting the strip are accomplished in accordance with said operational instructions;
assembling the plurality of separate frames from the plurality of structural elements;
injecting the plurality of separate frames with a high density insulating foam which bonds to the plurality of separate frames as the foam hardens, to a depth greater than the plurality of structural elements on at least one side of each of the plurality of separate frames to thereby form a metal-free foam faç
ade; and
applying a weatherproof coating to said foam faç
ade.
1 Assignment
0 Petitions
Accused Products
Abstract
Building design data is input into a computer to make a series of wall frames for a building. Operational instructions from the computer are used to fabricate members of the frames, fill the frames with insulating material and apply and external waterproof coating.
-
Citations
12 Claims
-
1. A method of producing prefabricated frames for a building, including the steps of:
-
inputting data relating to a design of the building into a computer program; automatically translating the data into designs of a plurality of separate frames, the plurality of separate frames comprising a plurality of structural elements and having a size and shape to be assembled together to complete the building; automatically producing operational instructions for roll-forming machinery and cutting machinery to fabricate the plurality of structural elements; roll-forming a strip with the roll-forming machinery; cutting the strip with the cutting machinery into the plurality of structural elements;
wherein the steps of roll-forming and cutting the strip are accomplished in accordance with said operational instructions;assembling the plurality of separate frames from the plurality of structural elements; injecting the plurality of separate frames with a high density insulating foam which bonds to the plurality of separate frames as the foam hardens, to a depth greater than the plurality of structural elements on at least one side of each of the plurality of separate frames to thereby form a metal-free foam faç
ade; andapplying a weatherproof coating to said foam faç
ade. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
-
-
11. A method of manufacturing a prefabricated wall frame for a house including the steps of:
-
inputting data relating to a design of the house into a computer program which automatically translates the data into designs of a plurality of separate wall frames that have a size and shape to be assembled together to complete the building of the house, which computer program automatically produces operational instructions for roll-forming a strip and cutting the strip into a plurality of structural elements, cutting service apertures in the plurality of structural elements, injecting the plurality of separate frames with expanded polystyrene foam which bonds to the plurality of separate frames as the foam hardens, to a depth greater than the plurality of structural elements on at least one side of the plurality of separate frames, cutting service channels into the foam and applying a coating material; automatically roll-forming, cutting and providing service apertures in the strip in accordance with said operational instructions to form the plurality of structural elements that form part of each of the plurality of separate frames that is required for building the entire house; assembling the plurality of the separate frames; filling the frames with foam in accordance with said operational instructions to thereby form a smooth external faç
ade;cutting service channels into the foam in accordance with said operational instructions; and applying said coating material to the external faç
ade in accordance with the operational instructions. - View Dependent Claims (12)
-
Specification