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Method and system for constructing pre-fabricated buildingMethod and system for constructing pre-fabricated building description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070163197, Method and system for constructing pre-fabricated building. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 60/754,110 filed Dec. 27, 2005. The disclosure of the provisional application is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates generally to building construction, and more specifically to a method and system for efficiently and economically constructing pre-fabricated residential and commercial buildings. [0004] 2. Description of the Prior Art [0005] Construction costs and quality of manufacture are major problems in the building trades. Many building systems have been proposed and used by others to cut costs and improve quality. Those prior art systems usually have some form of panelized pre-fabricated wall segment design. Many of such systems are in use worldwide. The shortcomings of the prior art pre-fabricated structures include, but are not limited to, inadequacies in the connection between the pre-fabricated panels, inefficient HVAC systems, and susceptibility to failure under high wind loads. [0006] One type of prior art building system provides complete walls segments with doors and windows. A shortcoming of this type of complete wall system is that it is cumbersome and does not possess the necessary commonality of use required for mass production. Further, often times there are problems associated with connecting these wall segments that results from variations in dimensional characteristics and leads to uneven gaps between the wall segments. Therefore, when typical connectors of the system are steel studs that fit within the panel track framework between wall segments, the web of the studs is incapable of being compressed, as would be needed if the gap spacing were too small, and similarly could not be extended automatically if the gap was oversized. Accordingly, what is needed in the art is a pre-fabricated building system that includes uniform wall segments and can be mass produced to reduce costs. [0007] Another shortcoming of the prior art is the lack of sufficient strength of the connection between wall segments. For example, the shape of the opposing track sides of the wall segments, when in contact with each other, is rectangular. A loose fitting stud is inserted between wall segments and attached using screws. However, the stress on the screws connecting the wall segments together is not ideal in that scenario. Accordingly, what is needed in the art is a means to join pre-fabricated wall segments that improves the strength of the connection. [0008] Still yet another shortcoming of the prior art is the materials that the wall segments comprise. Several manufactures fabricate wall panel segments with insulation, which are known in the art as structural panels. The structural insulated panels consist of wood or metal faced insulated cores bonded to each other. Metal and wood faced products are typically acceptable in commercial applications everywhere but meet with resistance in residential markets when used as walls. The preferred construction materials for walls in the residential market are cement-based products. [0009] Cement faced insulated tip up panels are available in the market place. These types of panels have gained wide acceptance in commercial buildings. However, a short-coming of the tip up panels is that they are so heavy that heavy equipment is needed for panel erection. Thereby making them unattractive to the residential market. Accordingly, what is need in the art is a pre-fabricated building system that includes wall panels fabricated with cement that are easy to maneuver without the use of specialized equipment. [0010] Another shortcoming of the prior art pre-fabricated building systems is that the HVAC systems are inefficient. For example, high velocity small diameter duct HVAC systems are in general use throughout the United States. Most installations with this type of system have two outlets per room and a secondary single remote location cold air return located elsewhere. Return duct openings must be sized to balance airflow with a minimal pressure drop to maintain maximum efficiency. If the return is too small, the pressure head suppresses airflow in the small diameter duct. Often times, each room does not have individual returns. Instead, the gap between the bottom of the door and the floor becomes the only means of exhaust. If the door is closed, the room becomes "stuffy". [0011] Further, it is not practical to provide each room with its own large return duct in addition to the two small diameter inlet ducts. This would also lead to an increase in air contaminants. For example, while the inlet ducting airflow is typically high of approximately 2000 feet per minute, the return duct velocity is typically less than approximately 50 feet per minute. The low velocity in the return air duct will cause dirt particles to settle out and collect in the duct itself in contrast to a high velocity airflow that would entrain the dirt particles as it flows through the ducting. Accordingly, what is needed in the art, is a pre-fabricated building system that incorporates a HVAC system that is highly efficient and hygienic. [0012] Another shortcoming of the prior art and conventional building methods is the susceptibility to failure from high wind loads. For example, recent hurricanes caused major structural damage to homes from inadequate retention of roof structures to walls. Various building departments responded to this problem by mandating the use of hurricane straps. These straps comprise a length of light gauge steel, typically placed at intervals equal to stud spacing that connect the wall structure with roofs and to other floor levels. The level of protection has improved thereby but is still inadequate for winds in excess of 150 mph. Accordingly, what is needed in the art is a pre-fabricated building system that has improved strength and resistance to high wind loads. [0013] It is, therefore, to the effective resolution of the aforementioned problems and shortcomings of the prior art that the present invention is directed. [0014] However, in view of the prior art at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how the identified needs could be fulfilled. SUMMARY OF THE INVENTION [0015] The invention provides a system and method for constructing pre-fabricated buildings. The system includes providing a plurality of wall panels wherein each said wall panel having a plurality of vertically disposed channel-shaped metal studs equidistantly disposed between a bottom plate and top plate; said wall panel having substantially rigid foam insert disposed between said channel-shaped metal studs wherein said insert having an aperture forming a conduit vertically disposed within said foam insert; providing an interior spline adapted to be inserted between a first wall panel and adjacent second wall panel adaptable to secure said first wall panel and second wall panel together wherein said interior spline comprises rigid foam with a pair of steel facing adhered on opposing faces thereto; providing a bottom track adaptable to receive said bottom plate of said plurality of wall panels; providing a top track adaptable to receive said top plate of said plurality of wall panels; providing a ceiling panel supported by a top portion of said wall panels; and providing a roof panel secured to said ceiling panel and wall panel. [0016] The components within the present invention's pre-fabricated wall panels are equivalent to standard open construction. Accordingly, a visual comparison of walls assembled from pre-fabricated wall panels with typical construction reveals some similarities. For example, both techniques are consistent with building codes for vertical spacing, facings, insulation, electrical, plumbing and HVAC. The major visual difference is in wall straightness, location, and squareness. This is a significant and important difference. The higher quality of the present invention's pre-fabricated wall panels is obtained by following strict quality control for incoming materials dimensional and performance specifications. [0017] The present invention was developed to provide structural insulated wall panels that have cement-like facings, are lightweight, pre-insulated, and easily erected by specially trained labor. An important advantage of the present invention using labor with composite classification assembly skills for electric, plumbing, heating and air conditioning is that a single crew can quickly perform all trade requirements. [0018] In the present invention, the accepted design of building walls with stud type framework is retained. However, the method of construction is changed as tasks performed on-site are instead completed in an off-site factory. A majority of currently common tasks, such as installing doors and windows, installing rough wiring, rough plumbing, placement of AC ducts, and applying wall facings, are done under strict quality control in the factory. For example, to build a four foot wall by traditional on site methods requires a carpenter, a block layer, an electrician, a plumber, HVAC tradesman, a dry wall crew and a painter. Time requirements are estimated in excess of one and one half hours to complete the work per four foot section. In contrast, the same four foot wall section can be constructed using the system and method of the present in approximately one minute. This rapid construction can be accomplished with a factory crew of ten workers. Further, it is estimated that labor costs are reduced to less than about 5% of traditional methods. This is accomplished by the factory placement of insulation, portions of rough wiring, and wall facings thereby eliminating the need for on site installation. [0019] A typical full size wall segment of the present invention is 8 feet tall and 4 feet wide. Other panel widths of one foot, two feet, and three feet, headers, panels with pre-installed windows or doors, panels with one end framed to math roof slope and panels for special wall heights or widths are also contemplated by the present invention. [0020] In accordance with the present invention, an interior space is defined by wall segments, ceiling panels and roof panels having steel and cement-faced surfaces. The space defined between the ceiling and roof panels (i.e., "attic space") is used as a ductless cold air return. Each room of a building is connected to the attic space, for example, by a standard 6''.times.10'' register well known in the art. Thus, restrictions to air circulation caused by using air return ducts are substantially removed. Further, typically only one high velocity small diameter duct is required per room. In the preferred embodiment, air circulation is maintained continuously and all rooms are maintained at approximately the same temperature making balancing the system unnecessary and each room is served by one directly connected duct to the air handler. [0021] The insulation of the attic space is equivalent to that used in commercial blast freezers. An interior temperature rise during the daylight hours is primarily a result of heat input from the occupants and from solar input through the windows. In the preferred embodiment, the windows are tempered double glazed argon fill E rated glass. Accordingly, the building will maintain a given inside temperature with little or no need for cooling or heating under normal conditions. The present invention incorporates approximately 10% minimum outside air. A separate controllable damper system is used in the nighttime hours to bring in up to 100% cooler outside air to lower the temperature in the home without the need for running the air conditioning equipment. Closing the damper in the daylight hours promotes keeping the house cool. Continue reading about Method and system for constructing pre-fabricated building... Full patent description for Method and system for constructing pre-fabricated building Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Method and system for constructing pre-fabricated building patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Method and system for constructing pre-fabricated building or other areas of interest. ### Previous Patent Application: Apparatus and method for installing insulation Next Patent Application: Laminate door stiffener with clip inserts Industry Class: Static structures (e.g., buildings) ### FreshPatents.com Support Thank you for viewing the Method and system for constructing pre-fabricated building patent info. 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