Automated construction system with interlocking panels

Abstract

An automated method of building construction utilizes a horizontal force to extrude a structural member formed from a plurality of elongate joists, upper panels, and lower panels. A framing machine includes an upper panel bay and feeder, a joist array and feeder, and a lower panel bay and feeder. The machine positions each joist into an installation position where fastening means forms the structural member, which is advanced out of the framing machine. Panel engagement means between the trailing edge of a panel and the leading edge of the next panel attach each panel to the next panel as the structural member is being formed. Additional means for insulating the structural member, installing pipes and wires, and an exterior finish may also be provided.

1 . A method of constructing a structural member for use in the construction of a building, comprising the steps of:
 (a) providing a plurality of vertical joists, arrayed horizontally, each joist having an upper edge and a lower edge, a plurality of horizontal upper panels, vertically stacked, above the arrayed joists, and a plurality of horizontal lower panels, vertically stacked, below the arrayed joists, wherein each of the upper and lower panels has a leading edge and a trailing edge;   (b) positioning a first joist in the joist array in an installation position;   (c) positioning a first upper panel and a first lower panel such that their leading edges align with the first joist in the installation position;   (d) fastening the first upper panel to the upper edge of a first joist, and fastening the first lower panel to the lower edge of the first joist;   (e) applying a horizontal force to the assembly created in steps (b) through (d) until the first joist is spaced apart from the installation position by a predetermined distance;   (f) positioning a second joist and the trailing edges of the first upper and first lower panel into the installation position;   (g) fastening the trailing edge of the first upper panel to the upper edge of the second joist, and fastening the trailing edge of the first lower panel to the lower edge of the second joist;   (h) positioning the leading edge of the next upper panel and the next lower panel in the installation position, and attaching the said leading edges to the second joist, abutted against the trailing edges of the first upper and lower panels respectively   (i) wherein the trailing edge of each panel and the leading edge of each next panel each comprise engagement means for engaging the leading edge of a next panel to the trailing edge of a panel, such that a horizontal pull force applied to the panel moves both the panel and the next panel;   (j) positioning the next joist in the installation position;   (k) fastening successive upper panels and successive lower panels to successive joists to create a structural member.   
   
   
       2 . The method of  claim 1  wherein the engagement means comprises a plurality of pins along one edge of panel, and which mate with a plurality of grooves within the edge of the adjacent panel. 
   
   
       3 . The method of  claim 1  wherein the horizontal force is applied in a continuous manner. 
   
   
       4 . The method of  claim 1  wherein the horizontal force is applied in an intermittent manner. 
   
   
       5 . The method of  claim 1  wherein the predetermined distance between joists is determined by a first and second barrier, where the first barrier is positioned at an installation position, and the second barrier is on a track allowing it to be variably spaced apart from the first barrier. 
   
   
       6 . The method of  claim 1  further comprising the step of applying an exterior surface finish to one or both of the upper and lower panels on the structural member. 
   
   
       7 . The method of  claim 6  wherein the surface finish is applied from a roll of surface finish material by a flat plate supported by a truss or posts connected to the framing machine, wherein the surface finish is pulled along with the structural member as it is being formed. 
   
   
       8 . The method of  claim 1  further comprising the step of applying an interior barrier surface to one or both of the upper and lower panels on the structural member. 
   
   
       9 . The method of  claim 8  wherein the barrier surface is applied from a roll of barrier material provided at the rear of the framing machine and placed between the joists and the lower panels or the upper panels. 
   
   
       10 . The method of  claim 1  further comprising the step of inserting mechanical lines into the structural member as it is being formed. 
   
   
       11 . The method of  claim 10  wherein the mechanical lines are attached to the first joist, threaded through the joists and applied from a roll or container. 
   
   
       12 . The method of  claim 11  wherein the mechanical lines comprise electrical wiring, cables, pipes, corrugated ventilation ducts, reinforcement mesh or conduits. 
   
   
       13 . The method of  claim 1  further comprising the step of inserting a retractable insulating tube into the structural member as it is being formed. 
   
   
       14 . The method of  claim 1  wherein the structural member is partially pre-assembled into Z-assemblies which are stacked in an array, wherein each Z-assembly comprises a joist, and upper panel, and a lower panel, wherein one panel is attached to the joist by a leading edge, and the other panel is attached to the joist by its trailing edge.