METHOD AND ARRANGEMENT FOR CONSTRUCTING AND INTERCONNECTING PREFABRICATED BUILDING MODULES
A modular building system allows for quickly and easily erecting prefabricated wall panels on a building foundation at a construction site. The system allows for manufacturing and installing, at a high level, complete budding components, using steps that are highly repeatable and scalable, resulting in construction that is quick and efficient, and easily performed at many types and locations of construction sites. A system in accordance with the invention comprises a wall panel, a floor panel and a roof panel. The wall panel comprises a horizontal member supported along a bottom horizontal edge, and a plurality of vertical studs integral to the horizontal member and extending vertically downward from the horizontal member. A floor panel comprises a rail disposed rigidly fixed to the foundation and defining an enclosure to receive the plurality of vertical studs of the wall panel to thereby vertically position the wall panel upon the foundation.
1 - 30 . (canceled)
31 : A method of installing one or more building components at a construction site, the method comprising:
lowering and coupling a first wall panel to a rail coupled to a foundation of a building, the first wall panel having a first vertical stud supported along a first vertical edge of the first wall panel;
lowering and coupling a second wall panel to the rail, the second wall panel having a second vertical stud supported along a second vertical edge of the second wall panel, wherein the first vertical stud and the second vertical stud denote a pair of male and female connectors; and
coupling the first vertical stud of the first wall panel with the second vertical stud of the second wall panel thereby coupling the first wall panel with the second wall panel.
32 : The method of claim 31 , wherein the first wall panel includes a first bottom horizontal surface with a first bottom connector configured to couple to a first top connector of the rail to secure the first wall panel to the rail, thereby vertically affixing the first wall panel to the foundation.
33 : The method of claim 32 , wherein the second wall panel includes a second bottom horizontal surface with a second bottom connector configured to couple to a second top connector of the rail to secure the second wall panel to the rail, thereby vertically affixing the second wall panel to the foundation.
34 : The method of claim 32 , wherein the first bottom connector comprises studs and the first top connector comprises recesses configured to receive the studs.
35 : The method of claim 32 , further comprising screw-fastening to the rail.
36 : The method of claim 33 , further comprising:
lowering the first wall panel towards the rail until at least a portion of the first bottom connector is inserted into the rail;
lowering the second wall panel towards the rail until at least a portion of the second bottom connector is inserted into the rail;
moving the second wall panel so that the second vertical edge aligns with the first vertical edge of the first wall panel;
fastening the first vertical stud and the second vertical stud together; and
securing the second bottom connector to the rail, thereby vertically affixing the second wall panel to the foundation, adjacent to the first wall panel, to form an extended wall on the foundation.
37 : The method of claim 31 , further comprising hooking the first wall panel on a top track along a top horizontal edge of the first wall panel before lowering the first wall panel onto the rail.
38 : The method of claim 31 , further comprising securing a roof panel over top horizontal edges of the first and second wall panels though a truss.
39 : The method of claim 38 , further comprising:
sensing, by a sensing element, locations of the first and second wall panels and the roof panel relative to each other and to the rail secured to a foundation; and
securing the first and second wall panels to the roof panel and the rail based on the sensed locations.
40 : The method of claim 31 , wherein the steps of lowering a first wall panel to a rail, lowering a second wall panel to the rail, and coupling the first wall panel with the second wall panel are performed automatically by a robot assembly.
41 : A method for installing one or more building components at a construction site, the method comprising:
lowering a first wall panel having a bottom horizontal surface with a first bottom connector onto a rail coupled to a foundation of a building, the rail having a top horizontal surface with a top connector, wherein the first wall panel comprises a first side connector;
coupling the first bottom connector to the top connector to secure the first prefabricated wall panel to the rail, thereby vertically affixing the first wall panel to the foundation;
lowering a second wall panel towards the rail, the second wall panel having a second bottom horizontal surface comprising a second bottom connector, until at least a portion of the second bottom connector is inserted into the rail, wherein the second wall panel comprising a second side connector matched to the first side connector;
moving the second wall panel so that the second side connector aligns with the first side connector;
fastening the first and second side connectors together; and
securing the second bottom connector to the rail, thereby vertically affixing the second wall panel to the foundation, adjacent to the first wall panel, to form an extended wall on the foundation.
42 : The method of claim 41 , further comprising securing a roof panel over top horizontal edges of the first and second wall panels though a truss.
43 : The method of claim 42 , further comprising coupling the roof panel with one or more other roof panels, wherein the roof panel includes one or more connectors comprising:
at least one first vertical stud supported along a first vertical face; and
at least one second vertical stud supported along a second vertical face opposite the first vertical face, wherein the at least one first vertical stud and the at least one second vertical stud comprise a pair of male and female connectors.
44 : The method of claim 43 , further comprising coupling the at least one first vertical stud of the roof panel with the at least one second vertical stud of the one or more other roof panels through a screw fastener.
45 : The method of claim 42 , further comprising:
sensing, by a sensing element, locations of the first and second wall panels and the roof panel relative to each other and to the rail secured to a foundation; and
securing the first and second wall panels to the roof panel and the rail based on the sensed locations.
46 : The method of claim 41 , wherein the steps of forming the extended wall on the foundation are performed automatically by a robot assembly.
47 : A system for installing one or more building components at a construction site, the building components comprising a first wall panel, having a first roof panel, and a second wall panel, having a second roof panel, the system comprising:
an installation mechanism configured to:
lower the first wall panel having a bottom horizontal surface with a first bottom connector onto a rail coupled to a foundation of a building, the rail having a top horizontal surface with a top connector, wherein the first wall panel comprises a first side connector;
couple the first bottom connector to the top connector to secure the first prefabricated wall panel to the rail, thereby vertically affixing the first wall panel to the foundation;
lower the second wall panel towards the rail, the second wall panel having a second bottom horizontal surface comprising a second bottom connector, until at least a portion of the second bottom connector is inserted into the rail, wherein the second wall panel comprising a second side connector matched to the first side connector;
move the second wall panel so that the second side connector aligns with the first side connector;
fasten the first and second side connectors together; and
secure the second bottom connector to the rail, thereby vertically affixing the second wall panel to the foundation, adjacent to the first wall panel, to form an extended wall on the foundation.
48 : The system of claim 47 , wherein the installation mechanism comprises a mechanical arrangement including at least a pulley.
49 : The system of claim 47 , wherein the installation mechanism comprises:
a robot assembly;
a sensing element for sensing the locations of the first and second wall panels and the first and second roof panels relative to each other and to the rail secured to the foundation; and
a processor, operatively coupled to the robot assembly and the sensing element, the processor executing computer-readable instructions that when executed, using the robot assembly and the sensing element, perform the steps of forming the extended wall on the foundation.
50 : The system of claim 47 , wherein, the installation mechanism is further configured to:
align the first and second roof panels relative to the first and second wall panels; and
secure the first and second roof panels to each other and to the first and second wall panels, respectively.