Method and system for constructing pre-fabricated building

Abstract

The present invention is a method and system for constructing pre-fabricated buildings. Wall panels are provided wherein each wall panel has a plurality of vertically disposed channel-shaped metal studs equidistantly disposed between a bottom plate and top plate. A substantially rigid foam insert is between each of the channel-shaped metal studs of a wall panel to provide insulation and structural support to the wall panel. The foam inserts each have an aperture forming a conduit vertically disposed within the foam insert. An interior spline is inserted between adjacent wall panels and provides the mechanical connection to secure the wall panels together. The interior spline comprises rigid foam with a pair of steel facing adhered on opposing faces of the spline.

1 . A method for constructing pre-fabricated buildings, the method comprising: 
 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 each 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 and adaptable to secure said first wall panel and second wall panel together wherein said interior spline comprising rigid foam having a pair of steel facings adhered on opposing faces thereto so that when said wall panels are secured together with said interior spline an enclosure is formed;    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.    
   
   
       2 . The method of  claim 1  further comprising providing a corner spline adapted to be inserted between a first wall panel and a substantially perpendicular second wall panel adaptable to secure said first wall panel and substantially perpendicular second wall panel together wherein said corner spline comprises rigid foam having a pair of steel corner facings adhered thereto.  
   
   
       3 . The plurality of wall panels of  claim 1  further having wall board secured on opposing faces.  
   
   
       4 . The method of  claim 2  further comprising providing an outer corner assembly having a bracket and wall board adaptable to secure over said corner spline so that a smooth transition is realized between said perpendicular wall panels.  
   
   
       5 . The method of  claim 4  further comprising providing an interior bracket adaptable to secure to an inside face of said corner spline.  
   
   
       6 . The interior spline of  claim 1  further comprising polystyrene.  
   
   
       7 . The steel facings of  claim 1  further comprising chamfered edges so that easy assembly of said plurality of wall panels is promoted.  
   
   
       8 . The method of  claim 1  further comprising providing a strip of foam adaptable to fit within said bottom track.  
   
   
       9 . The method of  claim 1  further comprising providing a brake metal hurricane strap adaptable to secure to a top portion of said ceiling panel, to an underside portion of said roof panel and to an exterior surface of said wall panel so that a continuous path is formed.  
   
   
       10 . The method of  claim 1  further comprising providing an attic space of said pre-fabricated building formed between said roof panels and ceiling panels wherein said attic space is in communication with living space of said prefabricated building and an HVAC system so that said attic space is climate controlled and improves efficacy of said HVAC system.  
   
   
       11 . A system for constructing pre-fabricated buildings, the system comprising: 
 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 each said channel-shaped metal studs wherein said insert having a aperture forming a conduit vertically disposed within said foam insert;    an interior spline adapted to be inserted between a first wall panel and adjacent second wall panel and adaptable to secure said first wall panel and second wall panel together wherein said interior spline comprising rigid foam having a pair of steel facings adhered on opposing faces thereto so that when said wall panels are secured together with said interior spline an enclosure is form;    a bottom track adaptable to receive said bottom plate of said plurality of wall panels;    a top track adaptable to receive top plate of said plurality of wall panels;    a ceiling panel supported by a top portion of said wall panels; and    a roof panel secured to said ceiling panel and wall panel.    
   
   
       12 . The system of  claim 11  further comprising a corner spline adapted to be inserted between a first wall panel and a substantially perpendicular second wall panel adaptable to secure said first wall panel and substantially perpendicular second wall panel together wherein said corner spline comprises rigid foam having a pair of steel corner facings adhered thereto.  
   
   
       13 . The plurality of wall panels of  claim 11  further having wall board secured on opposing faces.  
   
   
       14 . The system of  claim 12  further comprising an outer corner assembly having a bracket and wall board adaptable to secure over said corner spline so that a smooth transition is realized between said perpendicular wall panels.  
   
   
       15 . The system of  claim 14  further comprising an interior bracket adaptable to secure to an inside face of said corner spline.  
   
   
       16 . The steel facings of  claim 11  further comprising chamfered edges so that easy assembly of said plurality of wall panels is promoted.  
   
   
       17 . The system of  claim 11  further comprising a strip of foam adaptable to fit within said bottom track.  
   
   
       18 . The system of  claim 11  further comprising a brake metal hurricane strap adaptable to secure to a top portion of said ceiling panel, to an underside portion of said roof panel and to an exterior surface of said wall panel so that a continuous path is formed.  
   
   
       19 . The system of  claim 11  further comprising an attic space of said pre-fabricated building formed between said roof panels and ceiling panels wherein said attic space is in communication with living space of said prefabricated building and an HVAC system so that said attic space is climate controlled and improves efficacy of said HVAC system.  
   
   
       20 . The system of  claim 19  further comprising a damper system in communication with said HVAC system and ambient air so that fresh air is mixed with said re-circulated conditioned air of said living space.