Automated panel pressing construction system

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 installs a plurality of pegs into each joist and positions each joist into a forward installation position and a rear installation position. Panel press means press the upper and lower panels onto the pegs of each joist. Joist positioning means move successive joists into the installation positions, and push the structural member being formed outwards. 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) installing a plurality of pegs into the upper edge and the lower edge of the joists;   (c) positioning the first joist in the joist array in a forward installation position and a second joist in a rear installation position;   (d) positioning a first upper panel and a first lower panel such that their leading edges aligns with the first joist in the forward installation position, and their trailing edges align with the second joist in the rear installation position;   (e) pressing the first upper panel onto the pegs of the upper edge of the first and second joists, and pressing the first lower panel to the pegs of the lower edge of the first and second joists;   (f) applying a horizontal force to the assembly created in steps (a) through (e) until the second joist is positioned in the forward installation position;   (g) positioning a third joist into the rear installation position;   (h) pressing another upper panel and another lower panel to the pegs of the second and third joists;   (i) pressing successive upper panels and successive lower panels to successive joists by repeating steps (b) through (h), to create a structural member.   
   
   
       2 . The method of  claim 1  wherein the pegs comprise double-shanked nails. 
   
   
       3 . The method of  claim 1  wherein the pegs comprise triple-shanked nails. 
   
   
       4 . The method of  claim 1  wherein the pegs comprise a combination of double-shanked and triple-shanked nails. 
   
   
       5 . The method of  claim 1  wherein the pegs are pre-installed onto the joist prior to being arrayed in the joist array. 
   
   
       6 . The method of  claim 1  further comprising the step of inserting mechanical lines into the structural member as it is being formed. 
   
   
       7 . 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. 
   
   
       8 . The method of  claim 11  wherein the mechanical lines comprise electrical wiring, cables, pipes, corrugated venation ducts, reinforcement mesh, conduits or retractable insulation lines. 
   
   
       9 . The method of  claim 1  further comprising the step of inserting a stationary insulation line through the arrayed joists that sprays insulation into the structural member as it is being extruded out of the machine. 
   
   
       10 . 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, an upper rolled sheathing material, and a lower rolled sheathing material;   (b) installing a plurality of pegs into the upper edge and the lower edge of the joists;   (c) positioning the first joist in the joist array in a forward installation;   (d) pressing the upper rolled sheathing material to the upper edge of the joist and the lower rolled sheathing material to the lower edge of the joist in the forward installation position;   (e) pulling or pushing the first joist outwards and positioning a second joist into the forward installation position;   (f) pressing the upper rolled material to the upper edge of the second joist, and the lower rolled sheathing material to the lower edge of the second joist;   (g) repeating steps (b) through (f), to create a structural member.   
   
   
       11 . An apparatus for automating building construction comprising:
 (a) a joist feeder including a joist bay for holding a plurality of vertical joists, horizontally arrayed;   (b) an upper panel feeder, positioned above the joist feeder, comprising a panel bay for holding a plurality of horizontal panels, vertically arrayed;   (c) a lower panel feeder, positioned below the joist feeder, comprising a panel bay for holding a plurality of horizontal panels, vertically arrayed;   (d) fastening means for installing a plurality of pegs into upper and lower edges of the joists,   (e) panel press means for pressing the panels onto the pegs of the joists; and   (f) alignment means for positioning each successive joist in alignment with the panel press means.   
   
   
       12 . 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 upper panels, and a plurality of lower panels, wherein each of the upper and lower panels has a leading edge and a trailing edge;   (b) positioning the first joist in the joist array in a forward installation position and a second joist in a rear installation position;   (c) positioning a first upper panel and a first lower panel such that their leading edges aligns with the first joist in the forward installation position, and their trailing edges align with the second joist in the rear installation position;   (d) fastening the first upper panel onto the upper edge of the first and second joists, and fastening the first lower panel to the lower edge of the first and second joists;   (e) applying a horizontal force to the assembly created in steps (a) through (d) until the second joist is positioned in the forward installation position;   (f) positioning a third joist into the rear installation position;   (g) positioning and fastening the next upper panel and the next lower panel against the second and third joists; and   (h) repeating steps (f) and (g) to produce a structural member.   
   
   
       14 . An apparatus for automating building construction comprising:
 (a) a joist feeder including a joist bay for holding a plurality of vertical joists, horizontally arrayed;   (b) an upper panel bay for holding a plurality of horizontal panels,   (c) a lower panel bay for holding a plurality of horizontal panels,   (d) joist positioning means for moving successive joists into a forward and a rear installation position;   (e) upper panel actuating means comprising panel grasping means for grasping and moving an upper panel from the upper panel bay to a position aligned with the forward and rear installation positions;   (f) lower panel actuating means comprising panel grasping means for grasping and moving a lower panel from the lower panel bay to a position aligned with the forward and rear installation positions;   (g) fastening means for connecting upper panels to the upper edges of the joists; and   (h) fastening means for connecting lower panels to the lower edges of the joists.   
   
   
       15 . The apparatus of  claim 14  wherein the upper panel actuating means is moveable backwards and forwards and the panel grasping means is moveable upwards and downwards. 
   
   
       16 . The apparatus of  claim 14  wherein the lower panel actuating means may rotate from a vertical orientation to a horizontal orientation, and the lower panel grasping means may move upwards and downwards when the lower panel actuating means is in a horizontal orientation.