US20080168741A1 - Wall fabrication system and method - Google Patents

Wall fabrication system and method Download PDF

Info

Publication number
US20080168741A1
US20080168741A1 US11/676,002 US67600207A US2008168741A1 US 20080168741 A1 US20080168741 A1 US 20080168741A1 US 67600207 A US67600207 A US 67600207A US 2008168741 A1 US2008168741 A1 US 2008168741A1
Authority
US
United States
Prior art keywords
supports
wall section
covering
wall
flowable material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/676,002
Other languages
English (en)
Inventor
Peter Gilgan
Water Mitchell
Peter Vohsemer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mattamy Corp
Original Assignee
Mattamy Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mattamy Corp filed Critical Mattamy Corp
Assigned to THE MATTAMY CORPORATION reassignment THE MATTAMY CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GILGAN, PETER
Assigned to THE MATTAMY CORPORATION reassignment THE MATTAMY CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GILGAN, PETER, MITCHELL, WALTER, VOHSEMER, PETER
Publication of US20080168741A1 publication Critical patent/US20080168741A1/en
Priority to US13/216,938 priority Critical patent/US20110302877A1/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/386—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of unreconstituted or laminated wood

Definitions

  • the present invention relates generally to building construction and in particular to a wall fabrication system and method.
  • Housing is a critical aspect of social living. The construction of houses and other dwellings is therefore a well-known and highly refined art. Construction techniques and esthetic styles are well known for single family dwellings, detached and semi-detached houses, condominiums, apartment buildings, town houses, and the like.
  • Automation is also broad reaching and used heavily in a broad range of industries and is used to build cars, trucks, planes, electronics, appliances and many other products. Automation techniques are increasingly being applied to the housing industry, and indeed are used heavily in the manufacture of modular and panelized homes. Automation is not yet, however, widely applied to the manufacture of traditional site-built homes.
  • vapour barrier is also required.
  • Such a vapour barrier is usually provided via plastic sheets that are applied to the interior side face of the wall. The vapour barrier can be difficult to install, and in any event presents extra cost and time in the home construction process.
  • vapour barriers Another problem with vapour barriers is that mould growth and air leakage can result from punctures that can easily occur in the plastic sheets. Also, application of a moisture barrier in a damp area could actually trap existing moisture within the wall, particularly where the plastic sheeting becomes wrinkled, with all the attendant problems thereto.
  • Closed cell foam can be acquired in rigid sheets, and thus are not prone to sag in the same manner as fiberglass. However, the sheets of foam still need to be cut to size in order to fill irregular shaped cavities. Also, a vapour barrier can still be preferred when using sheets of closed cell foam.
  • a wall section comprising a first set of substantially parallel supports and a second set of substantially parallel supports disposed substantially perpendicular to the first set.
  • the parallel sets of supports are affixed to each other at their junctions.
  • the wall section also comprises a covering applied to one side of the supports.
  • the covering and the sets of supports define a plurality of cavities in the wall section.
  • the wall section also comprises a curable, flowable material that is downwardly injected into one or more of the cavities while the supports are in a horizontal position. Once the material is cured, the wall section can then be moved to the construction site and used to fabricate a home.
  • the wall section can further comprise a second covering that is applied to a second side of the supports that is opposite to the first side of the supports.
  • the foam material can adhere to both the first covering and the supports in such a manner that the covering is adhered to the supports by the foam material.
  • the covering can be drywall, or wood sheathing, or any other type of wall paneling.
  • the supports can be made from wood or metal or any other suitable material.
  • a torsional and tensional rigidity of the wall section can be increased thereby.
  • the thermal resistance (or R value) per inch of flowable material typically surpasses the R value per inch of traditional fiberglass bats.
  • R value typically surpasses the R value per inch of traditional fiberglass bats.
  • a traditional bat of 3.5 inch fiberglass has an R value of about 12
  • three inches of closed foam has an R value of about eighteen.
  • traditional fibreglass bats have an R value of about 3.4 per inch of fiberglass
  • closed cell foam has an R value of about six per inch.
  • the flowable material when the flowable material cures it can provide an air barrier from one side of the wall section to the other side of the wall section.
  • the flowable material can be chosen to have a low vapour permeance, and, when coupled with a vapour-barrier primer (applied as a paint to the drywall), then a vapour barrier can be formed that is suitable to substantially eliminate the need for plastic sheeting as a vapour barrier.
  • the flowable material can be closed cell foam. Closed cell foam can result in increased strength, increased insulation (thermal resistance), and act as an air barrier and has a low vapour permeance.
  • the flowable material can be open cell foam.
  • the wall section comprises a first set of substantially parallel supports and a second set of substantially parallel supports that are disposed substantially perpendicular to the first set.
  • the parallel and vertical supports are affixed to each other at their junctions.
  • the wall section also comprises a covering positioned on one side of the supports. The covering and the sets of supports define cavities in the wall section.
  • the method can further comprise applying a second covering to a second side of the supports that is opposite to the first side of the supports.
  • the method can further comprise applying the flowable material to both the first covering and portions of the supports that are perpendicular to the first covering and waiting until the foam material cures such that the covering is adhered to the supports.
  • the wall sections comprise a first set of substantially parallel supports and a second set of substantially parallel supports disposed substantially perpendicular to the first set of supports.
  • the wall sections include a covering applied to one side of the supports. The covering and the sets of supports each define cavities in each wall section.
  • the system can also comprise one or more insulation stations for receiving wall sections from the framing stations and for injecting a curable flowable material downwardly into one or more of the cavities while the supports are in a horizontal position.
  • the framing stations and the insulation stations can be configured to produce and insulate, respectively, wall sections that have different configurations.
  • the system can further comprise automation equipment, such as robotic equipment, for the framing stations and the insulation stations.
  • automation equipment such as robotic equipment
  • the system can further comprise a computer configured to control the automation equipment in the framing stations and the insulation stations according to a production schedule in order to continuously produce and insulate a plurality of wall sections having different configurations.
  • an assembly line comprises one or more framing stations and one or more insulation stations.
  • the framing stations are configured to build a wall frame consisting of wall studs and a covering such as drywall.
  • the wall studs and drywall define cavities in the frame which are to be insulated.
  • mechanical components such as electrical, plumbing, central vacuum, telephone and the like can be installed into the wall section.
  • the wall section is then transferred to the insulation station.
  • the insulation station is configured to fill the cavities in the wall frame with closed cell foam which is injected in flowable form into each cavity.
  • FIG. 1 is an isometric view of a wall section
  • FIG. 2 is a schematic representation of an assembly line for manufacturing and insulating the wall section of FIG. 1 ;
  • FIG. 3 is an isometric view of the insulation station of the assembly line of FIG. 2 ;
  • FIG. 4 shows the insulation station of FIG. 3 in greater detail
  • FIG. 5 is a partial cross section showing a wall cavity being filled using the injector of the insulation station of FIG. 3 ;
  • FIG. 6 shows the wall section of FIG. 3 after having been filled by the insulation station of FIG. 3 ;
  • FIG. 7 is a partial sectional view of the wall section in FIG. 6 with a second sheet of drywall being applied thereto;
  • FIG. 8 is a partial sectional view of the wall section of FIG. 6 after the second sheet of drywall has been attached thereto.
  • FIG. 9 shows a variation on the wall section of FIG. 6 .
  • FIG. 10 shows the wall section of FIG. 9 with various programming parameters identified thereon.
  • Wall section 50 comprises a plurality of substantially parallel vertical studs 54 transversely affixed to a plurality of substantially parallel horizontal studs 58 . Not all vertical studs 54 and horizontal studs 58 are labeled in FIG. 1 . Studs 54 , 58 define a frame 60 that is covered on one side by drywall 62 or other type of covering such as plywood, wood or the like. Studs 54 , 58 act as supports for wall section 50 .
  • Studs 54 , 58 can be wood and/or metal and/or any other suitable type of home framing material for a traditional site-built home. Studs 54 , 58 are affixed to each other using nails, staples and/or any other type of suitable fastener. Drywall 62 (typically a plurality of sheets of drywall) is affixed to frame 60 with nails, staples, screw and/or glue or any other type of suitable fastener.
  • drywall 62 can be only partially affixed to frame 60 , so that drywall 62 is secured to frame 60 so as to simply hold drywall 62 in place so that wall section 50 can be further processed, but not secured to the extent that would traditionally be needed to fully secure drywall 62 to frame 60 in final installation on site.
  • the Ontario Building Code 1977 states that “Spacing of 5 ⁇ 8′′ long steel drill screws shall be not more than 300 mm along supports, except that on vertical surfaces the screws may be spaced at 400 mm where the supports are no more than 400 mm o/c.”
  • the teachings herein can obviate traditional fasteners and/or mitigate the number of screws that are required according to the Ontario Building Code.
  • Wall section 50 is thus characterized by a plurality of cavities 64 - 1 , 64 - 2 , 64 - 3 . . . 64 - 9 . (Generically, cavity 64 , and collectively, cavities 64 ). Wall section 50 , in a present embodiment, is also characterized by a door 68 , and a window 70 .
  • each wall section 50 will also include all mechanical components, including, for example electrical, plumbing, heating ventilation air-conditioning (“HVAC”) conduits, central vacuum conduits, telephone, cable television, and/or Ethernet and/or outlets relating to any of the foregoing.
  • HVAC heating ventilation air-conditioning
  • wall section 50 in its entirety, is typically constructed on an assembly line 74 in a manufacturing facility.
  • Assembly line 74 thus includes one or more framing station(s) 78 and one or more insulation station(s) 82 .
  • Insulation station 82 will be discussed in greater detail below.
  • Framing station 78 is configured to produce wall section 50 . It is also contemplated that assembly line 74 is “flexible”, so that while framing station 78 is configured to produce wall section 50 , framing station 78 is also configured to produce wall sections that have configurations that are different than wall section 50 . In other words, various wall sections produced on assembly line 74 can be different, according to a desired production run for different configurations of traditional site-built homes. Assembly line 74 can also be fully or partially automated, with computers instructing robotic equipment to manufacture each wall section.
  • assembly line 74 is substantially automated, including the transfer of wall sections from station 78 to station 82 .
  • assembly line 74 includes a central scheduling computer 86 that maintains a production schedule 90 with production runs for station 78 and station 82 .
  • Production schedule 90 thus includes instructions for the configuration of wall section 50 and configurations for every other wall section that is to be produced using framing station 78 and insulated at insulation station 82 .
  • Computer 86 is configured to deliver instructions to operators and/or robotic equipment in framing station 78 as to the configuration of each wall section to be produced.
  • Computer 86 is also configured to notify insulation station 82 as to the configuration of each wall section 78 that has been produced so that insulation station 82 can fulfill the insulation task.
  • insulation station 82 is shown in greater detail, which shows wall section 50 within station 82 .
  • insulation station 82 includes a robotic X-Y Gantry 91 .
  • Gantry 91 includes a pair of rails 94 .
  • a transverse rail 98 is positioned perpendicular to rails 94 .
  • Transverse rail 98 is motorized and configured to run along the length of rails 94 .
  • An injector 102 is mounted to transverse rail 98 and is movable along the length of rail 98 .
  • a computerized controller 106 is connected to gantry 91 and can issue instructions thereto in order to move injector 102 to any location above wall section 50 . While the present embodiment contemplates a gantry 91 , it should be understood that other robotic configurations are also contemplated.
  • Controller 106 is in turn connected to computer 86 and is configured to receive instructions from computer 86 as to the configuration of the particular wall section 50 within station 82 as found on production schedule 90 .
  • Injector 102 is configured to dispense closed cell foam 110 in a flowable form into each cavity 64 .
  • Injector 102 is connected to a reservoir (not shown) of foam that is located proximal to station 82 .
  • rails 94 and 98 are substantially horizontal and wall section 50 is also positioned substantially horizontally, so that injector 102 is above wall section 102 and all foam 110 dispensed from injector 102 flows substantially downwardly.
  • Controller 106 is thus configured to instruct gantry 91 so as to move injector 102 above the extent of each cavity 64 , and to issue instructions to a valve associated with injector 102 that causes injector 102 to either dispense foam 110 , or to cause injector 102 to “shut off” and not dispense foam.
  • the valve can also be variable so that the rate of flow of foam 110 is variable. Whether injector 102 is dispensing foam or not, injector 102 is movable along rails 94 , 98 according to instructions from controller 106 .
  • Wall section 50 a located within station 82 , while being filled with foam 110 by injector 102 , is shown in greater detail.
  • Wall section 50 a includes cavities 64 a and a window 70 a .
  • Wall section 50 a is also shown with mechanical components, in the form of electrical conduit 114 a run within cavities 64 a - 6 , 64 a - 7 and 64 a - 8 .
  • controller 106 is preprogrammed with a plurality of paths to follow in order to fill each cavity 64 .
  • Controller 106 is preprogrammed to move injector 102 within each cavity 64 a according to each predefined path, and dispense a bead of foam 110 along that path.
  • Controller 106 is also preprogrammed to move injector 102 between each cavity 64 a without dispensing any foam.
  • the rate of travel of injector 102 , and flow rate of foam 110 can be chosen in order to optimize speed of filling each cavity 64 , reduce and/or minimize the overall amount of travel of injector 102 within each cavity 64 a and/or reduce and/or minimize the amount of travel of injector 102 between each cavity 64 a where injector 102 is not dispensing any foam.
  • the size of the bead that is injected is chosen so as to optimize any settling and/or expansion that may occur within each cavity 64 a and the cure times of the foam. It can be desired to control the manufacturing steps for each station 78 and 82 such that the cycle time for each station 78 and 82 are substantially the same, and thus the operation of injector 102 can be configured accordingly.
  • injector 102 for further control over-filling of cavities 64 a , it can also be desired to configure injector 102 to be movable along an axis perpendicular to rail 98 , in order to control the depth of foam 110 .
  • the depth of foam 110 for each cavity is chosen so as to be slightly less than the depth of studs 54 , 58 .
  • the actual depth of foam that is dispensed may be less than the final fill depth, in order to account for any expansion of foam that can occur during the curing process.
  • wall section 50 a is shown having cavities 64 a therein completely filled with foam 110 by a plurality of beads 122 of foam 110 . It will be noted that the pattern of fill for each cavity 64 a is unique to that cavity. Table I provides an exemplary summary of each pattern of fill.
  • Table I The contents of Table I can thus be converted into programming instructions for controller 106 , with each cavity 64 a being filled by injector 102 in the order according the sequence in Table I.
  • a second covering can be affixed to frame 60 .
  • the second covering is in the form of drywall 126 .
  • FIG. 8 in particular shows that the depth of foam is such that a small gap exists between foam 110 and drywall 126 .
  • foam 110 adheres to drywall 62 , thereby affixing drywall 62 to frame 60 in a manner that can be more secure than at least some prior art methods which include the sole use of nails and/or staples and/or glue. Since the use of mechanical fasteners (e.g. nails and/or staples) can be substantially eliminated, or at least reduced, drywall 62 is much less susceptible to the phenomenon of “nail-pops” whereby drywall nails, over time, appear to be driven out of wooden studs 54 , 58 and protrude from the surface of drywall 62 , with an unsightly effect.
  • mechanical fasteners e.g. nails and/or staples
  • the depth of foam 110 is substantially uniform.
  • the insulating properties are also substantially uniform along the length of wall section 50 .
  • the mechanical adherence of drywall 62 to frame 60 is substantially uniform throughout the entire extent of drywall 62 .
  • each wall section 50 can obviate the need for a traditional vapour-barrier of plastic sheeting to be applied, particularly when a vapour-barrier primer is applied to the wall section 50 .
  • each wall section 50 with foam 110 can increase the overall strength, both in torsion and in tension, of each wall section 50 .
  • wall sections manufactured according to the teachings herein are more resilient during the shipping process and less susceptible to damage than traditional, prior art wall sections.
  • the teachings herein can, in certain applications, obviate the use of fasteners for drywall 62 to stud 58 altogether, as the adhesion between the foam and the drywall 62 and stud 58 is sufficient.
  • the use of closed cell foam can permit the reduction in the thickness of an exterior wall cavity from six inches to four inches, since the closed cell foam has an R value per inch that is greater than the R value per inch of traditional fiberglass insulation bats. This reduction in wall cavity thickness reduces the amount of lumber used and reduces stresses on the environment.
  • a four inch wall cavity using the teachings herein can have the same, or better, air-conditioning and heating costs as a six inch wall cavity that employs traditional fiberglass bats.
  • an engineered ventilated station can be configured to thereby reduce exposure to fumes given off during application.
  • foam When foam is sprayed vertically into wall cavities on a construction site, the operator has to wear ventilation gear, yet an engineered ventilation system can mean that the operator need wear no gear when foam is sprayed using the teachings herein.
  • an engineered ventilation system can mean that the operator need wear no gear when foam is sprayed using the teachings herein.
  • the option exists to substantially completely recover the gases and prevent them from release into environment, and there by substantially reduce off-gassing into the environment.
  • FIGS. 9 and 10 a variation on wall section 50 a is indicated as wall section 50 b .
  • FIGS. 9 and 10 show the specific sequence of passes for each cavity of wall section 50 b .
  • Appendix I hereto describes the application parameters of foam for each cavity of wall section 50 b.
  • the present invention thus provides, amongst other things, a novel system and method for manufacturing wall sections of houses by providing an assembly line for producing and insulating wall sections.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
US11/676,002 2007-01-11 2007-02-16 Wall fabrication system and method Abandoned US20080168741A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US13/216,938 US20110302877A1 (en) 2007-01-11 2011-08-24 Wall Fabrication System and Method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA2,573,687 2007-01-11
CA002573687A CA2573687C (fr) 2007-01-11 2007-01-11 Systeme et methode de fabrication de cloisons

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US13/216,938 Continuation US20110302877A1 (en) 2007-01-11 2011-08-24 Wall Fabrication System and Method

Publications (1)

Publication Number Publication Date
US20080168741A1 true US20080168741A1 (en) 2008-07-17

Family

ID=39103114

Family Applications (2)

Application Number Title Priority Date Filing Date
US11/676,002 Abandoned US20080168741A1 (en) 2007-01-11 2007-02-16 Wall fabrication system and method
US13/216,938 Abandoned US20110302877A1 (en) 2007-01-11 2011-08-24 Wall Fabrication System and Method

Family Applications After (1)

Application Number Title Priority Date Filing Date
US13/216,938 Abandoned US20110302877A1 (en) 2007-01-11 2011-08-24 Wall Fabrication System and Method

Country Status (3)

Country Link
US (2) US20080168741A1 (fr)
CA (1) CA2573687C (fr)
WO (1) WO2008083478A1 (fr)

Cited By (35)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100095625A1 (en) * 2008-10-20 2010-04-22 Zine-Eddine Boutaghou Rigid foam insulating panel with compressible joint
NL2006194A (nl) * 2010-02-12 2011-08-15 Mopac Systems Internat S A Werkwijze, inrichting en een computerprogramma voor het vervaardigen van een voorgeã¯soleerd skeletbouwsegment.
WO2011098984A1 (fr) * 2010-02-12 2011-08-18 Mopac Systems International S.A. Procédé, dispositif et programme informatique permettant de fabriquer un segment d'ossature pré-isolé
US20130178951A1 (en) * 2012-01-11 2013-07-11 Ncr Corporation Techniques for configuring physical spaces
US20140013678A1 (en) * 2011-03-14 2014-01-16 Alain Marc Yves Deverini Prefabricated Module Used for Living Accommodations
US20140311061A1 (en) * 2012-07-09 2014-10-23 Alexander Freimark Keller Solar Power Unit And System
US8950132B2 (en) 2010-06-08 2015-02-10 Innovative Building Technologies, Llc Premanufactured structures for constructing buildings
US8978324B2 (en) 2010-06-08 2015-03-17 Innovative Building Technologies, Llc Pre-manufactured utility wall
US9027307B2 (en) 2010-06-08 2015-05-12 Innovative Building Technologies, Llc Construction system and method for constructing buildings using premanufactured structures
EP2283987A3 (fr) * 2009-08-14 2016-02-24 aluplast GmbH Dispositif d'application de mousse pour éléments de chambre creuse
US9493940B2 (en) 2010-06-08 2016-11-15 Innovative Building Technologies, Llc Slab construction system and method for constructing multi-story buildings using pre-manufactured structures
US20180058069A1 (en) * 2016-09-01 2018-03-01 Bryan Scott Mello Method and apparatus for manufacturing building panels
US10041289B2 (en) 2014-08-30 2018-08-07 Innovative Building Technologies, Llc Interface between a floor panel and a panel track
US20180340326A1 (en) * 2017-05-24 2018-11-29 Timothy B. Pirrung Modular building components, systems, and methods thereof
US10260250B2 (en) 2014-08-30 2019-04-16 Innovative Building Technologies, Llc Diaphragm to lateral support coupling in a structure
US10323428B2 (en) 2017-05-12 2019-06-18 Innovative Building Technologies, Llc Sequence for constructing a building from prefabricated components
US10329764B2 (en) 2014-08-30 2019-06-25 Innovative Building Technologies, Llc Prefabricated demising and end walls
US10364572B2 (en) 2014-08-30 2019-07-30 Innovative Building Technologies, Llc Prefabricated wall panel for utility installation
US20190330839A1 (en) * 2016-11-15 2019-10-31 Werk Eins Gmbh Habitation block and method for producing thermal insulation
US10487493B2 (en) 2017-05-12 2019-11-26 Innovative Building Technologies, Llc Building design and construction using prefabricated components
WO2019237030A1 (fr) * 2018-06-08 2019-12-12 U.S. Precision Construction, Llc Systèmes et procédés de production de composants destinés à être utilisés dans la construction d'unités de construction modulaires
US10508442B2 (en) 2016-03-07 2019-12-17 Innovative Building Technologies, Llc Floor and ceiling panel for slab-free floor system of a building
US10676923B2 (en) 2016-03-07 2020-06-09 Innovative Building Technologies, Llc Waterproofing assemblies and prefabricated wall panels including the same
US10724228B2 (en) 2017-05-12 2020-07-28 Innovative Building Technologies, Llc Building assemblies and methods for constructing a building using pre-assembled floor-ceiling panels and walls
EP2610048B1 (fr) * 2011-12-29 2020-08-19 Kurtz GmbH Dispositif de moussage destiné à la fabrication de plaques isolantes
US10875218B2 (en) 2016-09-01 2020-12-29 Bryan Scott Mello Method and apparatus for manufacturing building panels
US10900224B2 (en) 2016-03-07 2021-01-26 Innovative Building Technologies, Llc Prefabricated demising wall with external conduit engagement features
US10961710B2 (en) 2016-03-07 2021-03-30 Innovative Building Technologies, Llc Pre-assembled wall panel for utility installation
US11054148B2 (en) 2014-08-30 2021-07-06 Innovative Building Technologies, Llc Heated floor and ceiling panel with a corrugated layer for modular use in buildings
CN113165176A (zh) * 2018-11-21 2021-07-23 巴斯夫欧洲公司 制造隔热构件的方法和系统
US11098475B2 (en) 2017-05-12 2021-08-24 Innovative Building Technologies, Llc Building system with a diaphragm provided by pre-fabricated floor panels
US11447963B2 (en) 2017-09-25 2022-09-20 Canvas Construction, Inc. Automated wall finishing system and method
US11499325B2 (en) 2017-03-31 2022-11-15 Canvas Construction, Inc. Automated drywall painting system and method
US11724404B2 (en) 2019-02-21 2023-08-15 Canvas Construction, Inc. Surface finish quality evaluation system and method
US12297076B2 (en) 2018-11-14 2025-05-13 Innovative Building Technologies, Llc Modular stairwell and elevator shaft system and method

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BR102017013895B1 (pt) * 2017-06-27 2023-11-14 Zeenni Engenharia E Construções Ltda Aperfeiçoamentos introduzidos em módulo de parede ventilada de concreto armado para construção de edificações em geral e respectivo sistema construtivo industrializado
US20200199871A1 (en) * 2017-09-11 2020-06-25 10163511 Canada Inc. Wall module for buildings
WO2021083969A1 (fr) * 2019-11-01 2021-05-06 Basf Se Ensemble paroi pré-isolé
US11642687B2 (en) * 2020-02-13 2023-05-09 Covestro Llc Methods and systems for manufacturing foam wall structures
US20240165647A1 (en) * 2022-11-18 2024-05-23 Boxabl Inc. Planar component assembly line
NL2035689B1 (en) * 2023-08-28 2025-03-11 Well Solutions Bv Structural panel element production method
DE102023135130A1 (de) * 2023-12-14 2025-06-18 Weinmann Holzbausystemtechnik Gmbh Verfahren zur Herstellung von Gebäudeelementen

Citations (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3258889A (en) * 1962-04-16 1966-07-05 Upson Co Prefabricated stud panel with foam insulation connector
US3949529A (en) * 1973-03-26 1976-04-13 W. H. Porter, Inc. Insulating structural assembly and stud member for forming same
US4114333A (en) * 1977-04-05 1978-09-19 Jones Harold E Wall panel unit
US4259028A (en) * 1978-04-17 1981-03-31 Efficiency Production, Inc. Water and debris impermeable trench box panel
US4305538A (en) * 1979-11-02 1981-12-15 Robert Schultz Portable apparatus for assembling frame structures
US4723385A (en) * 1985-11-04 1988-02-09 Hadak Security Ab Fire resistant wall construction
US5666780A (en) * 1995-12-14 1997-09-16 Guardian Industries Corp. Fiberglass/dry adhesive mixture and method of applying same in a uniform manner
US5822940A (en) * 1996-07-17 1998-10-20 Carlin; Steven Composite wall panel
US6226943B1 (en) * 1999-01-26 2001-05-08 The Dow Chemical Company Wall system and insulation panel therefor
US6430889B1 (en) * 2001-04-27 2002-08-13 Signature Door Co. Inc. Framing structure for openings, particularly doorway side lights
US6564521B1 (en) * 2000-05-12 2003-05-20 Brown Paul A Structural sandwich panels and method of manufacture of structural sandwich panels
US20050188649A1 (en) * 2003-06-06 2005-09-01 Hans T. Hagen, Jr. Insulated stud panel and mehod of making such
US7127856B2 (en) * 2003-06-06 2006-10-31 Hans T. Hagen, Jr. Insulated stud panel and method of making such
US7343715B2 (en) * 2001-05-17 2008-03-18 Toray Industries, Inc. Sound-proof wall made of FRP, and method of producing the same

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3641724A (en) * 1969-03-29 1972-02-15 James Palmer Box beam wall construction
US4914883A (en) * 1986-10-22 1990-04-10 Foamseal, Inc. Method of bonding structural support channels to a panel
US4856244A (en) * 1987-06-01 1989-08-15 Clapp Guy C Tilt-wall concrete panel and method of fabricating buildings therewith
US5639405A (en) * 1995-09-01 1997-06-17 Elizabeth Erikson Trust Method for providing selective control of a gas assisted plastic injection apparatus
US5641368A (en) * 1995-12-14 1997-06-24 Guardian Fiberglass, Inc. Fiberglass spray insulation system and method with reduced density
CA2182242C (fr) * 1996-07-29 1999-07-06 Michel V. Richard Panneau mural prefabrique et pre-isole

Patent Citations (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3258889A (en) * 1962-04-16 1966-07-05 Upson Co Prefabricated stud panel with foam insulation connector
US3949529A (en) * 1973-03-26 1976-04-13 W. H. Porter, Inc. Insulating structural assembly and stud member for forming same
US4114333A (en) * 1977-04-05 1978-09-19 Jones Harold E Wall panel unit
US4259028A (en) * 1978-04-17 1981-03-31 Efficiency Production, Inc. Water and debris impermeable trench box panel
US4305538A (en) * 1979-11-02 1981-12-15 Robert Schultz Portable apparatus for assembling frame structures
US4723385A (en) * 1985-11-04 1988-02-09 Hadak Security Ab Fire resistant wall construction
US5666780A (en) * 1995-12-14 1997-09-16 Guardian Industries Corp. Fiberglass/dry adhesive mixture and method of applying same in a uniform manner
US5822940A (en) * 1996-07-17 1998-10-20 Carlin; Steven Composite wall panel
US6226943B1 (en) * 1999-01-26 2001-05-08 The Dow Chemical Company Wall system and insulation panel therefor
US6564521B1 (en) * 2000-05-12 2003-05-20 Brown Paul A Structural sandwich panels and method of manufacture of structural sandwich panels
US6430889B1 (en) * 2001-04-27 2002-08-13 Signature Door Co. Inc. Framing structure for openings, particularly doorway side lights
US7343715B2 (en) * 2001-05-17 2008-03-18 Toray Industries, Inc. Sound-proof wall made of FRP, and method of producing the same
US20050188649A1 (en) * 2003-06-06 2005-09-01 Hans T. Hagen, Jr. Insulated stud panel and mehod of making such
US7127856B2 (en) * 2003-06-06 2006-10-31 Hans T. Hagen, Jr. Insulated stud panel and method of making such
US7168216B2 (en) * 2003-06-06 2007-01-30 Hans T. Hagen, Jr. Insulated stud panel and method of making such

Cited By (63)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100095625A1 (en) * 2008-10-20 2010-04-22 Zine-Eddine Boutaghou Rigid foam insulating panel with compressible joint
EP2283987A3 (fr) * 2009-08-14 2016-02-24 aluplast GmbH Dispositif d'application de mousse pour éléments de chambre creuse
EP2835242A3 (fr) * 2010-02-12 2015-08-12 Mopac Systems International S.A. Procédé, dispositif et programme informatique pour fabriquer un segment de cadrage de squelette pré-isolé
NL2006194A (nl) * 2010-02-12 2011-08-15 Mopac Systems Internat S A Werkwijze, inrichting en een computerprogramma voor het vervaardigen van een voorgeã¯soleerd skeletbouwsegment.
WO2011098984A1 (fr) * 2010-02-12 2011-08-18 Mopac Systems International S.A. Procédé, dispositif et programme informatique permettant de fabriquer un segment d'ossature pré-isolé
BE1019669A5 (nl) * 2010-02-12 2012-09-04 Mopac Systems Internat S A Werkwiize, inrichting en een computerprogramma voor het vervaardigen van een voorgeîsoleerd skeletbouwsegment.
US20130037984A1 (en) * 2010-02-12 2013-02-14 Mopac Systems International S.A. Method, device and a computer program for manufacturing a pre-insulated skeleton framing segment
US9522492B2 (en) * 2010-02-12 2016-12-20 Mopac Systems International S.A. Method, device and a computer program for manufacturing a pre-insulated skeleton framing segment
US10183425B2 (en) * 2010-02-12 2019-01-22 Mopac Systems International S.A. Method, device and a computer program for manufacturing a pre-insulated skeleton framing segment
US20150375434A1 (en) * 2010-02-12 2015-12-31 Mopac Systems International S.A. Method, device and a computer program for manufacturing a pre- insulated skeleton framing segment
AU2011213957B2 (en) * 2010-02-12 2015-05-07 Mac Investments B.V. Method, device and a computer program for manufacturing a pre-insulated skeleton framing segment
US9162381B2 (en) * 2010-02-12 2015-10-20 Mopac Systems International S.A. Method, device and a computer program for manufacturing a pre-insulated skeleton framing segment
US9382709B2 (en) 2010-06-08 2016-07-05 Innovative Building Technologies, Llc Premanufactured structures for constructing buildings
US9027307B2 (en) 2010-06-08 2015-05-12 Innovative Building Technologies, Llc Construction system and method for constructing buildings using premanufactured structures
US8978324B2 (en) 2010-06-08 2015-03-17 Innovative Building Technologies, Llc Pre-manufactured utility wall
US8950132B2 (en) 2010-06-08 2015-02-10 Innovative Building Technologies, Llc Premanufactured structures for constructing buildings
US9493940B2 (en) 2010-06-08 2016-11-15 Innovative Building Technologies, Llc Slab construction system and method for constructing multi-story buildings using pre-manufactured structures
US10190309B2 (en) 2010-06-08 2019-01-29 Innovative Building Technologies, Llc Slab construction system and method for constructing multi-story buildings using pre-manufactured structures
US10145103B2 (en) 2010-06-08 2018-12-04 Innovative Building Technologies, Llc Premanufactured structures for constructing buildings
US20140013678A1 (en) * 2011-03-14 2014-01-16 Alain Marc Yves Deverini Prefabricated Module Used for Living Accommodations
EP2610048B1 (fr) * 2011-12-29 2020-08-19 Kurtz GmbH Dispositif de moussage destiné à la fabrication de plaques isolantes
US9176492B2 (en) * 2012-01-11 2015-11-03 Ncr Corporation Techniques for configuring physical spaces
US20130178951A1 (en) * 2012-01-11 2013-07-11 Ncr Corporation Techniques for configuring physical spaces
US9243816B2 (en) * 2012-07-09 2016-01-26 Alexander Freimark Keller Solar power unit and system
US20140311061A1 (en) * 2012-07-09 2014-10-23 Alexander Freimark Keller Solar Power Unit And System
US10364572B2 (en) 2014-08-30 2019-07-30 Innovative Building Technologies, Llc Prefabricated wall panel for utility installation
US10975590B2 (en) 2014-08-30 2021-04-13 Innovative Building Technologies, Llc Diaphragm to lateral support coupling in a structure
US10260250B2 (en) 2014-08-30 2019-04-16 Innovative Building Technologies, Llc Diaphragm to lateral support coupling in a structure
US11060286B2 (en) 2014-08-30 2021-07-13 Innovative Building Technologies, Llc Prefabricated wall panel for utility installation
US10329764B2 (en) 2014-08-30 2019-06-25 Innovative Building Technologies, Llc Prefabricated demising and end walls
US10041289B2 (en) 2014-08-30 2018-08-07 Innovative Building Technologies, Llc Interface between a floor panel and a panel track
US11054148B2 (en) 2014-08-30 2021-07-06 Innovative Building Technologies, Llc Heated floor and ceiling panel with a corrugated layer for modular use in buildings
US10508442B2 (en) 2016-03-07 2019-12-17 Innovative Building Technologies, Llc Floor and ceiling panel for slab-free floor system of a building
US10676923B2 (en) 2016-03-07 2020-06-09 Innovative Building Technologies, Llc Waterproofing assemblies and prefabricated wall panels including the same
US10900224B2 (en) 2016-03-07 2021-01-26 Innovative Building Technologies, Llc Prefabricated demising wall with external conduit engagement features
US10961710B2 (en) 2016-03-07 2021-03-30 Innovative Building Technologies, Llc Pre-assembled wall panel for utility installation
US10500772B2 (en) * 2016-09-01 2019-12-10 Bryan Scott Mello Expanded foam-filled building panel
US20180058069A1 (en) * 2016-09-01 2018-03-01 Bryan Scott Mello Method and apparatus for manufacturing building panels
US10875218B2 (en) 2016-09-01 2020-12-29 Bryan Scott Mello Method and apparatus for manufacturing building panels
US20190330839A1 (en) * 2016-11-15 2019-10-31 Werk Eins Gmbh Habitation block and method for producing thermal insulation
US10889979B2 (en) * 2016-11-15 2021-01-12 Werk Eins Gmbh Habitation block and method for producing thermal insulation
US12345057B2 (en) 2017-03-31 2025-07-01 Canvas Construction, Inc. Automated drywall painting system and method
US11499325B2 (en) 2017-03-31 2022-11-15 Canvas Construction, Inc. Automated drywall painting system and method
US11525270B2 (en) 2017-03-31 2022-12-13 Canvas Construction, Inc. Automated drywall planning system and method
US10724228B2 (en) 2017-05-12 2020-07-28 Innovative Building Technologies, Llc Building assemblies and methods for constructing a building using pre-assembled floor-ceiling panels and walls
US10487493B2 (en) 2017-05-12 2019-11-26 Innovative Building Technologies, Llc Building design and construction using prefabricated components
US10323428B2 (en) 2017-05-12 2019-06-18 Innovative Building Technologies, Llc Sequence for constructing a building from prefabricated components
US11098475B2 (en) 2017-05-12 2021-08-24 Innovative Building Technologies, Llc Building system with a diaphragm provided by pre-fabricated floor panels
US11118341B2 (en) * 2017-05-24 2021-09-14 Timothy B. Pirrung Modular building components, systems, and methods thereof
US10538905B2 (en) * 2017-05-24 2020-01-21 Timothy B. Pirrung Modular building components, systems, and methods thereof
US20180340326A1 (en) * 2017-05-24 2018-11-29 Timothy B. Pirrung Modular building components, systems, and methods thereof
US11905719B2 (en) 2017-09-25 2024-02-20 Canvas Construction, Inc. Automated wall finishing system and method
US11447963B2 (en) 2017-09-25 2022-09-20 Canvas Construction, Inc. Automated wall finishing system and method
EP4219104A1 (fr) * 2018-06-08 2023-08-02 Buildz, LLC Systèmes et procédés de production de composants destinés à être utilisés dans la construction d'unités de construction modulaires
US11236519B2 (en) 2018-06-08 2022-02-01 Buildz, Llc Automated systems and methods for floor and ceiling units in the construction of modular building units
US11851897B2 (en) 2018-06-08 2023-12-26 Buildz, Llc Systems and methods of producing components for use in the construction of modular building units
US11873652B2 (en) 2018-06-08 2024-01-16 Buildz, Llc Automated systems and methods for floor and ceiling units in the construction of modular building units
US12110698B2 (en) 2018-06-08 2024-10-08 Buildz, Llc Systems and methods of producing components for use in the construction of modular building units
US12180724B2 (en) 2018-06-08 2024-12-31 Buildz, Llc Automated systems and methods for floor and ceiling units in the construction of modular building units
WO2019237030A1 (fr) * 2018-06-08 2019-12-12 U.S. Precision Construction, Llc Systèmes et procédés de production de composants destinés à être utilisés dans la construction d'unités de construction modulaires
US12297076B2 (en) 2018-11-14 2025-05-13 Innovative Building Technologies, Llc Modular stairwell and elevator shaft system and method
CN113165176A (zh) * 2018-11-21 2021-07-23 巴斯夫欧洲公司 制造隔热构件的方法和系统
US11724404B2 (en) 2019-02-21 2023-08-15 Canvas Construction, Inc. Surface finish quality evaluation system and method

Also Published As

Publication number Publication date
US20110302877A1 (en) 2011-12-15
CA2573687C (fr) 2009-06-30
CA2573687A1 (fr) 2008-02-17
WO2008083478A1 (fr) 2008-07-17

Similar Documents

Publication Publication Date Title
CA2573687C (fr) Systeme et methode de fabrication de cloisons
US9222261B2 (en) Prefabricated structural building frame and method of making the same
MXPA06012083A (es) Materiales compuestos de fibra reforzada y estructuras de construccion que comprenden materiales compuestos de fibra reforzada.
US20090044471A1 (en) Fiber-Reinforced Composites and Building Structures Comprising Fiber-Reinforced Composites
US10422142B2 (en) Exterior polymer-based brick building material
US20020069600A1 (en) Composite structural building panels and systems and method for erecting a structure using such panels
EP1327038A1 (fr) Plaque de recouvrement
US20180171641A1 (en) Building material cladding components and methods
WO2021083969A1 (fr) Ensemble paroi pré-isolé
US20250092692A1 (en) Pour in place foam insulation for building components
AU2001240899A1 (en) Panel
DE10229984A1 (de) Saunaelemente mit einer Kernschicht aus Polypropylen-Schaumstoff
US20100126114A1 (en) Apparatus for cladding an insulation member, a composite cladded insulation member, and methods of forming and installing same
US20060070322A1 (en) Constructional element and method for its manufacture
WO2007082356A1 (fr) Panneau composite d'isolation thermique, son procede de production et structures de batiments constituees de tels panneaux
US11505942B2 (en) Method of manufacturing OSB with extruded polymer bands
US20240392565A1 (en) Method of manufacture and use of osb with extruded polymer bands
EP4310266A1 (fr) Panneau de construction stratifié et son procédé de fabrication
WO2025207397A1 (fr) Éléments de construction volumétriques et panélisés multifonctionnels fabriqués par fabrication avancée
US20240316895A1 (en) Flat construction element, comprising an insulating panel, a cover plate and a made-to-measure duct course
DE19705542A1 (de) Kanalbausatz
WO2008103669A1 (fr) Structures de portes comprenant des composites renforcés par des fibres
WO2002009930A2 (fr) Procede de fabrication d'un panneau composite
DE10018710A1 (de) Leichtbauwand, Verfahren als auch System zu deren Herstellung sowie Wandelement
DE2328419A1 (de) Verfahren und system fugenlos gepresster bauelemente aus einem nicht steigfaehigen gemisch von organischen fasern bzw. spaenen und bindemitteln, zur erstellung vorfabrizierter haeuser

Legal Events

Date Code Title Description
AS Assignment

Owner name: THE MATTAMY CORPORATION, CANADA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:GILGAN, PETER;REEL/FRAME:018902/0982

Effective date: 20070212

AS Assignment

Owner name: THE MATTAMY CORPORATION, CANADA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:GILGAN, PETER;MITCHELL, WALTER;VOHSEMER, PETER;REEL/FRAME:019203/0171

Effective date: 20070323

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION