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Prefabricated structural building frame and method of making the same

  • US 9,222,261 B2
  • Filed: 07/07/2010
  • Issued: 12/29/2015
  • Est. Priority Date: 07/07/2009
  • Status: Active Grant
First Claim
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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.

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