US3699622A

US3699622A - Method and apparatus for making wall panels

Info

Publication number: US3699622A
Application number: US139731A
Authority: US
Inventors: Donald V Frydenberg
Original assignee: Clary Corp
Current assignee: Clary Corp
Priority date: 1971-05-03
Filing date: 1971-05-03
Publication date: 1972-10-24
Anticipated expiration: 1989-10-24

Abstract

Disclosed method and apparatus continuously forms building wall panels using pre-formed sub-assemblies having centrally positioned locators thereon. Locating notches are formed in the top and bottom frame plate members at the centers for various window, door and post components. The plate members are fed continuously and as the locators drop into the notches, thereby properly locating the sub-assemblies, they are carried to a nailing station where they are fastened to the plate members.

Description

United States Patent Frydenberg [4 Oct. 24, 1972 [54] METHOD AND APPARATUS FOR MAKING WALL PANELS [72] Inventor: Donald V. Frydenberg, Arlington,

Tex.

[73] Assignee: Clary Corporation, San Gabriel,

Calif.

[22] Filed: May 3, 1971 [21] Appl. No.: 139,731

[52] US. Cl. ..29/155 R, 29/200 B, 29/469 [51] Int. Cl. ....B23p 17/00, B23p 19/00, B23p 21/00 [58] Field of Search ..29/ 155 R, 200 B, 200 A, 469

Bowers, Jr ..29/200 B Rosenblo'm ..29/4 1 7 Primary ExaminerThomas H. Eager Att0rney--Fred N. Schwend [57] ABSTRACT 7 post components. The plate members are fed continuously and as the locators drop into the notches, thereby properly locating the sub-assemblies, they are [56] References Cited carried to a nailing station 'where they are fastened to UNITED STATES PATENTS the plate members. 7

3,413,703 12/1968 Sanford 155 14 Claims, 15 Drawing Figures LI 1 l H H PATENTEDHB 24 1972 SHEET 1 OF 4 P'A'TENTEDHEI 1912 3,699,622

SHEET 2 OF 4 I N VEN TOR. Domw V. FQYDENBEPG /l/z /4J PATENTEUum 24 I972 SHEET 3 BF 4 IN VENTOR, 00mm V fbvacwsms PATENTEDIJBI 24 I972 SHEET l 0F 4 INVENTOR;

3 DONALD V. f'evozlvafea min/4.54

. 1 METHOD AND APPARATUS FOR MAKING WALL PANELS BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a method and apparatus for pre-fabricating wall panels for buildings.

2. Description of the Prior Art Wall panels have been pre-fabricated heretofore using conveyor systems wherein spaced top and bottom plate members are intermittantly advanced endwise along an assembly table from one station to the next. Differentstructural members such as studs, sheathing, etc., are secured at. different stations while the partially completed wall panel remains stationary at such stations.

In some'cases, the plate members are notched beforehand, as disclosed, for example, in the US. Pat. to Bamford No. 2,574,163, to receive the ends of the various through studs and other studs forming parts of the window and door sub-assemblies. In other cases, the cations of such studs are marked on the plate members by pencil or the like. In either case, such locations for the studs forming part of sub-assemblies are determined based on an architects drawing which generally shows only the dimensions from an outside wall to the centers of the windows and doors, or to the centers of any inside walls.

The locations of the studs forming part of such subassemblies are then calculated so that they will be located equal distances from the centers and are marked off on the plate members. Later, at one of the stations, the studs are located in their proper marked positions and are nailed to the plate members to form a skelton wall panel, after which, at subsequent stations, the sheathing and other components are secured to the wall panel.

Although such methods of assembly are satisfactory, they are often time consuming and confusing to the workmen, particularly because the window'and door subassemblies are usually of different widths. Therefore, the studs forming part of such sub-assemblies must be spaced different and equal distancesfrom the subassembly centers as set forth in the architects drawings. Also, any wall junction posts and similar subassemblies must be located on opposite sides of center locations found in the drawings. This requires the workman to determine not only the distance from the center of a window, door, or the like to its side ends but also to add an additional amount for clearance, etc., depending on the particular type of window or door to be installed. For example, a metal window generally requires a different spacing between its sides and the adjacent window sub-assembly forming studs than does a wooden door. Also, the centers of the various through studs must be accurately laid off at normally 16 inch centers.

SUMMARY OF THE INVENTION According to the present invention various sub-assemblies, i.e., window opening frames, door opening frames, corner posts, wall junction posts, etc., are preassembled. Locating means are fonned on the plate members in the form ofnotches located only at the centers for the various sub-assemblies or sub-assembly frames, and as the plate members are fed along the assembly table, appropriate ones of the pre-assembled sub-assemblies having locating elements at the centers thereof are laid along the plate members and as the sub-assemblies become properly lined up relative to the wall panel being formed, the locating elements drop into the notches to accurately locate the sub-assemblies in position and to carry them to a nailing station ready to be nailed in place. At such nailing station, the sub-assemblies are nailed to the plate members. Also the through studs are located on 16 inch centers, wherever the spacing between the sub-assemblies permits, and are also nailed in place.

Such arrangement enables the plate members and resulting wall panel to be moved at a continuous rate of speed along the assembly table. It also reduces the complexity of assemblying the wall panels, enables a greater speed of assembly, reduces the amount of assembly labor and greatly reduces the possibility of error in properly locating the various components of such' wall panels.

I BRIEF DESCRIPTION OF THE DRAWINGS.

FIG. 2 is a portion of an architects drawing appropriate forthe wall panel section of FIG. 1.

FIG. 3 is a perspective view of a window sub-assembly with locators attached thereto.

FIG. 4 is a perspective view of a wall junction post sub-assembly with locators attached thereto.

FIG. 5 is fragmentary plan view of a plate member and part of a sub-assembly frame located in proper relative positions by means of the present invention. I

FIG. 6 is sectional view taken along line 6-6 of F IG. 5. I

FIG. 7 is a plan view of part of an assembly apparatus constructed according to the present invention.

FIG. 8 is a plan view of part of a frame plate member marked to indicate the centers. of various sub-assemblies.

FIG. 9 is a side view showing the subassembly placement station.

. FIG. 10 is a sectional view illustrating the plate notching mechanism and is taken along the line 10--10 of FIG. 7.

FIG. 11 is a sectional view taken substantially along the line 11-11 ofFIG. 7.

FIG. 12 is a sectional view taken along line l2-l2 of FIG. 7, illustrating the nailing station.

FIG. 13 is a sectional view taken along the line 13- 13 of FIG. 12.

FIG. 14 is a sectional view taken along the line 14- 14 of FIG. 7.

FIG. 15 is a sectional view taken along line l5-15 of FIG. 14.

DETAILED DESCRIPTION OF PREFERRED METHOD AND APPARATUS FIG. 1 illustrates a partially completed or skeleton frame 11 of a wall panel fabricated according to the present invention. The skeleton comprises top and

bottom plate members

12 and 13, respectively, a door subassembly 14, a window sub-assembly 15, a wall juncture post sub-assembly 16, and corner post sub-assembly 17, all suitably nailed at their ends to the plate members.

Through studs, i.e., 18, are shown nailed to the plate members on 16-inch centers. However, the distance between a through stud and the outer stud of an adjacent sub-assembly may vary depending on the distance between adjacent sub-assemblies, although such spacing should'normally be 16 inches or less.

The skeleton frame 11 may form either a complete wall panel of a building or a modular unit which is later secured to other units of similar or different lengths to form a complete wall panel.

FIG. 2 shows part of an architects drawing wherein the wall panel 11 of FIG. 1 is depicted at 11a to be an outside wall including a door 14a, a window 15a, an inner wall 20 and an adjoining outside wall 21. It will be noted that the drawing indicates only the dimensions from the outside edge of an outside wall panel to the centers of the windows, doors, and interior walls. Window and door schedules or lists (not shown) are also generally provided on the drawing which indicate the type and nominal sizes of the windows and doors from which are determined the spacing of the various sub-assembly studs, i.e., 23 and 24, defining the openings for such windows and doors.

In accordance with the present invention the various sub-assemblies, i.e., 14, 15 16 and 17 are pre-assembled. FIG. 3 illustrates a window sub-assembly comprising outside studs 25, inside studs 26, header 27, still 28 and cripples 29, all formed generally of 2 X 4 -inch members securely nailed together.

Also, in accordance with the invention, locators 33 are securely mounted on the top and bottom ends of each sub-assembly and these are located exactly midway between the side ends, i.e., between the outer studs 25 in FIG. 3. As shown in FIGS. and 6, each such locator comprises a thin semi-cylindrical metal or plastic body 34 and an integral semi-circular flange 35, the latter having nail holes 36 formed therein. The body 34 has a length approximately equal to one half the thickness of each plate member.

In order to secure the locators 33 in proper position at the ends of the sub-assemblies, and to facilitate fabrication and handling of the sub assemblies, each locator is nailed or otherwise fastened to a wooden l X 4 -inch member 37 which is, in turn, secured by nails 39 to the end of the sub-assembly. As shown in FIG. 6, the upper edge of the locator 33 is located flush with the upper edge of the member 37 so that the axis of the locator lies coincident with the plane of the adjacent face of the sub-assembly. FIG. 4 illustrates a wall junction post sub-assembly comprising three2 X 4 -

inch members

38, 39, and 40 nailed together and having locators 33 secured thereto by short lengths of l X 4 -inch members 41. Here, also, the locators are located exactly midway between the outer edges of the

members

38 and 40.

Referring to FIGS. 7 to 15, and to FIG. 11 in particular, the wall panel assembling apparatus comprises a table formed of angle guide members 42 and 43 supported in spaced relation to each other by structural side frame members 44 and 49, respectively.

Spaced endless chains 45, FIGS. 14 and 15, are driven along a portion of the table, over sprockets 46,

and along side the guide members 42 and 43. The sprockets are carried by shafts, 47 and 147, the latter being driven by a continuously running motor 48. Such chains have drive spurs 50 extending-from certain of the links thereof whichengage the undersides of the

plate members

12 and 13 to positively drive the latter in concert with each other along the table.

Rollers

51, 52 and 53 are rotatably mounted on guide frame members 59 secured to the frame members 44 and 49, and are located above the lefthand sprockets 46 at progressively shorter distances above the table so that they may progressively impale the plate members to greater extents upon the drive spurs 50.

As the trailing end of each plate member, i.e., 12, approaches the drive chain 45 a new plate member, i.e., 12a, is fed in abutment therewith so as to form a continuous length plate member.

Splicing devices generally indicated at 55 and 56 are located over the plate members at a splicing station 49 to permanently splice the abutting ends of separate plate members while the latter are continuously advanced over the table. Since such splicing devices do not form the subject matter of the present invention, they are not disclosed in detail herein. Thereafter, marks, i.e., 47, FIG. 8, are preferably applied to the plate members by crayons or the like to indicate the placement of the various sub-assemblies. This may be done automatically by means, not shown, or manually by reference to pre-marked measuring tapes, not shown, which are laid along the plate members and marked according to dimensions on the architechs drawings. Thereafter, the plate members pass through a notching station 58' where semi-circular notches 60, FIG. 10 and 11, are formed in the plate members, coincident with the marks 57. Such notches are substantially of the same radii as the outside radii of locators 33.

The notching device comprises a pair or rotating cu'tters 62 and 63 carried at the outer ends of a shaft 64 which is continuously driven by a motor 65. The shaft 64 is rotatably supported in bearings carried by arms 66 and 67 which, in turn, are carried by a rock shaft 68 journaled in bearing brackets 70, the shaft 68 being secured to an arm 71 which is connected to the piston rod of an air cylinder 72 anchored to a cross frame member 73. The motor 65 is attached to a cross brace 74 secured between the arms 66 and 67.

The air cylinder 72 is suitably actuated as the marks 57 pass under the cutters 62 and 63 to form the notches 60 with the centers thereof coincident with such marks. Control of the cylinder 72 may be accomplished under manual control by valve means, not shown, or by photoelectric control means, now shown but well known in the art. It will be noted that the notches are cut to depths equal to one half the diameters of the cutters 62 and 63.

Subsequent to the notching operation, the plate members are fed through a sub-assembly placement station 75 (see also FIG. 9) where various prefabricated sub-assemblies, i.e., 15, as determined by the nominal sizes found in drawings, are placed, one at a time, between the

plate members

12 and 13 with the locators 33 resting on the upper edges of the plate members. Locating dogs 76 are pivotally supported at 77 and are held by springs 78 in positions to yieldably maintain a sub-assembly in a fixed position as the plate members move thereunder. When the notches 60 in the plate members become aligned with the locators the latter drop into the notches, thereby locating the subassemblies in proper positions. The dogs 76 now yield as the sub-assemblies are carried by the plate members toward a nailing station 80.

As shown particularly in FIG. 7, l2, and 13, endless conveyor chains 81 and 82 are supported by sprockets 83 at opposite ends thereof to move along the under edges of the plate members in the vicinity of the nailing station 80. The sprockets 83 ahead of the nailing station 80 are carried by a shaft 84 which is driven by the motor 48 through an endless chain drive 84 so as to move the chains 81 and 82 in concert with the plate members.

Each of the chains 81 nd 82 carries stud locating devices generally indicated at 86 which are spaced apart on 16-inch centers. The devices 86 each comprises a bracket 87 suitably secured to a link of its respective chain and is pivotally connected at 88 to a U-shaped dog 90 adapted to embrace an adjacent end of a through stud, i.e., 18. A torsion spring 91 normally holds the dog 90 in its upper illustrated position. Various through studs are fitted over the locating dogs 90 prior to passage through the nailing station. This may be accomplished manually or by suitable automatic handling mechanism, not shown. In those cases where a sub-assembly passes over a dog 90 it will lower the dog into, an ineffective position against the action of its spring 91.

Nailing devices generally indicated at 92 are suitably supported at the nailing station 80

adjacent plate members

12 and 13 to nail such plate members to the various through studs and sub-assemblies as they pass through the nailing station to form the skeleton wall panel. Such nailing devices are well known in the art. Nailing devices of this nature may be commercially obtained, for example, from the .Paslode Company, Skokie, Illinois and may be actuated either manually at an appropriate time as each through stud or stud of a sub-assembly passes the same or they may be actuated automatically under control of suitable sensing device, not shown, which sense the passage of the studs and sub-assemblies past the nailing devices.

In a subsequent station, now shown, sheathing and other components are fastened to the various assembled plate members, studs, and sub-assemblies to form the completed wall panel. Thereafter, traveling cut-off saws, not shown, cut the continuous wall panel thus formed into complete wall panels or into modular wall panel sections which may be later assembled together to form a complete wall panel.

I claim: frame extending between said said plate 1. The method of forming a building wall panel having spaced plate members, at least one sub-assembly frame extending between said plate members, and through studs extending between said plate members which comprises forming said sub-assembly frame,

forming first locating means on at least one of the top and bottom ends of said frame and centrally of the I side ends of said frame,

forming second locating means on at least one of said plate members at the center for said frame,

placing said frame intermediate said plate members,

moving said plate members endwise relative to said frame whereby to cause said first locating means to engage said second locating means,

thereafter fastening said frame to said plate mem- 5 bers, and fastening said studs to said plate members.

2. The method according to claim 1 comprising forming said first locating means on both said top and bottom ends of said frame and forming said second locating means on both of said plate members.

3. The method of forming a building wall panel having spaced plate members, at least one sub-assembly frame extending between said plate members, and through studs extending between said plate members which comprises forming said subasseinbly frame,

forming first locating means on. the top and bottom ends of said frame and centrally of the side ends of said frame,

forming second locating means on said plate members at the center for said frame,

placing said frame intermediate said plate members,

moving said plate members endwise relative to said frame whereby to cause said first locating means to engage said second locating means and to move said frame to a fastening station, and

fastening said frame and said studs to said plate members at said fastening station.

4. The method according to claim 3 comprising moving said plate members endwise at a continuous rate of speed.

5. The method of forming a building wall panel having spaced plate. members,

at least one sub-assembly frame extending between said plate members,

and through studs extending between said plate members which comprises pre-forming'said subassembly frame,

forming outwardly extending locating elements on the top and bottom ends of said frame and centrally of the side ends of said frame,

forming locating notches in said plate member at the center for said frame,

placing said frame intermediate said plate members with said locating element resting on said plate members under the influence of gravity,

moving said plate members endwise relative to said frame whereby to enable said locating elements to drop into said locating notches and to cause said plate members to move said frame to a fastening station,

and fastening said frame and said studs to said plate members at said fastening station.

6. The method forming a building wall panel having spaced plate members,

at least one sub-assembly frame extending between said plate members, and through studs extending between said plate members which comprises preforming said sub-assembly frame, forming outwardly and co-axially extending semicylindrical locating elements on the top and bottom ends of said frame with the axes of said elements extending midway between the side ends of said frame,

forming co-axially extending semi-cylindrical notches in said plate members with the axes of said notches extending coincident with the center for said frame,

placing said frame intermediate said plate members with said locating elements resting on said plate members under the influence of gravity,

moving said plate members endwise relative to said frame whereby to enable said locating elements to drop into said notches and to cam said plate move said frame to a fastening station,

spacing said studs along said plate members,

7. Apparatus for forming a building wall panel having spaced plate members,

at least one sub-assembly frame extending between said plate members and through studs extending between said plate members which comprises means for moving said plate members endwise successively through a plurality of stations,

means at one of said stations for forming a locating formation on at least one of said plate members,

said locating formation being located at the center for said frame,

means at a subsequent station for yieldably maintaining said frame stationary intermediate said plate members,

said frame having at least one locating element extending therefrom centrally of the side ends of said frame,

said locating formation being effective to engage said locating element whereby to-move said frame with said plate members,

and means at a subsequent station for fastening said 35 frame and said studs to said plate members.

8. Apparatus according to claim 7 wherein said second mentioned means forms locating formations on both of said plate members,

9. Apparatus according to claim 8 wherein said locating formations comprise semi-cylindrical notches in said plate members, and

said locating elements comprise semi-cylindrical projections adapted to fit in said notches.

10. Apparatus according to claim 9 wherein said locating elements rest against said plate members and drop into said notches under the influence of gravity.

11. Apparatus for forming a building wall panel having spaced plate members,

at least one sub-assembly frame having side ends and extending between said plate members, and through studs-extending between said plate members which comprises means for moving said plate members end-wise,

at least one of said plate members having 'a locating formation thereon,

said locating formation being located at the center for said frame,

means for yieldably maintaining said frame stationary intermediate said plate member;

at least one locating element extending from said frame centrally of said side ends of said frame, said locating formation being effective to engage sa1d locating element whereby to move said frame with said plate members, and

means for thereafter fastening said frame and said studs to said plate members.

12. Apparatus according to claim 11 wherein said locating formation comprises a semi-cylindrical notch in said one plate member,

and

said locating element comprises a semi-cylindrical projection adapted to fit in said notch.

13. Apparatus according to claim 12 comprising a second semi-cylindrical notch in the other of said plate members and aligned with said first mentioned notch, and

a second semi-cylindrical projection on said frame and aligned with said first mentioned projection,

said second projection being adopted to fit in said second notch.

14. Apparatus according to claim 11 wherein said locating element comprises a semi-cylindrical shell having a semi-circular flange at one end thereof, and

means fastening said flange to said frame.

Claims

1. The method of forming a building wall panel having spaced plate members, at least one sub-assembly frame extending between said plate members, and through studs extending between said plate members which comprises forming said sub-assembly frame, forming first locating means on at least one of the top and bottom ends of said frame and centrally of the side ends of said frame, forming second locating means on at least one of said plate members at the center for said frame, placing said frame intermediate said plate members, moving said plate members endwise relative to said frame whereby to cause said first locating means to engage said second locating means, thereafter fastening said frame to said plate members, and fastening said studs to said plate members.

3. The method of forming a building wall panel having spaced plate members, at least one sub-assembly frame extending between said plate members, and through studs extending between said plate members which comprises forming said sub-assembly frame, forming first locating means on the top and bottom ends of said frame and centrally of the side ends of said frame, forming second locating means on said plate members at the center for said frame, placing said frame intermediate said plate members, moving said plate members endwise relative to said frame whereby to cause said first locating means to engage said second locating means and to move said frame to a fastening station, and fastening said frame and said studs to said plate members at said fastening station.

5. The method of forming a building wall panel having spaced plate members, at least one sub-assembly frame extending between said plate members, and through studs extending between said plate members which comprises pre-forming said sub-assembly frame, forming outwardly extending locating elements on the top and bottom ends of said frame and centrally of the side ends of said frame, forming locating notches in said plate member at the center for said frame, placing said frame intermediate said plate members with said locating element resting on said plate members under the influence of gravity, moving said plate members endwise relative to said frame whereby to enable said locating elements to drop into said locating notches and to cause said plate members to move said frame to a fastening station, and fastening said frame and said studs to said plate members at said fastening station.

6. The method forming a building wall panel having spaced plate members, at least one sub-assembly frame extending between said plate members, and through studs extending between said plate members which comprises pre-forming said sub-assembly frame, forming outwardly and co-axially extending semi-cylindrical locating elements on the top and bottom ends of said frame with the axes of said elements extending midway between the side ends of said frame, forming co-axially extending semi-cylindrical notches in said plate members with the axes of said notches extending coincident with the center for said frame, placing said frame intermediate said plate members with saiD locating elements resting on said plate members under the influence of gravity, moving said plate members endwise relative to said frame whereby to enable said locating elements to drop into said notches and to cam said plate move said frame to a fastening station, spacing said studs along said plate members, and fastening said frame and said studs to said plate members at said fastening station.

7. Apparatus for forming a building wall panel having spaced plate members, at least one sub-assembly frame extending between said plate members and through studs extending between said plate members which comprises means for moving said plate members endwise successively through a plurality of stations, means at one of said stations for forming a locating formation on at least one of said plate members, said locating formation being located at the center for said frame, means at a subsequent station for yieldably maintaining said frame stationary intermediate said plate members, said frame having at least one locating element extending therefrom centrally of the side ends of said frame, said locating formation being effective to engage said locating element whereby to move said frame with said plate members, and means at a subsequent station for fastening said frame and said studs to said plate members.

8. Apparatus according to claim 7 wherein said second mentioned means forms locating formations on both of said plate members, and said frame has locating elements extending from the top and bottom ends thereof and engageable with respective ones of said locating formation.

9. Apparatus according to claim 8 wherein said locating formations comprise semi-cylindrical notches in said plate members, and said locating elements comprise semi-cylindrical projections adapted to fit in said notches.

11. Apparatus for forming a building wall panel having spaced plate members, at least one sub-assembly frame having side ends and extending between said plate members, and through studs extending between said plate members which comprises means for moving said plate members end-wise, at least one of said plate members having a locating formation thereon, said locating formation being located at the center for said frame, means for yieldably maintaining said frame stationary intermediate said plate member; at least one locating element extending from said frame centrally of said side ends of said frame, said locating formation being effective to engage said locating element whereby to move said frame with said plate members, and means for thereafter fastening said frame and said studs to said plate members.

12. Apparatus according to claim 11 wherein said locating formation comprises a semi-cylindrical notch in said one plate member, and said locating element comprises a semi-cylindrical projection adapted to fit in said notch.

13. Apparatus according to claim 12 comprising a second semi-cylindrical notch in the other of said plate members and aligned with said first mentioned notch, and a second semi-cylindrical projection on said frame and aligned with said first mentioned projection, said second projection being adopted to fit in said second notch.

14. Apparatus according to claim 11 wherein said locating element comprises a semi-cylindrical shell having a semi-circular flange at one end thereof, and means fastening said flange to said frame.