SCALABLE DYNAMIC FRAME SYSTEM

Abstract

An assembled frame for a structure in the building can be formed from multiple different types of building blocks for a frame. The assembled frame for the structure in the building is formed with the multiple different types of building blocks for the assembled frame in a manufacturing facility, and then shipped as the assembled frame to a construction site. The multiple different types of individual building blocks for the frame can at least include two or more of i) metal beams/strut framework, ii) metal angle frames, iii) metal cross connects, and iv) metal mating blocks.

Description

RELATED APPLICATION

This application claims priority under 35 USC 119 to U.S. provisional patent application No. 63/297,208, titled “A SCALABLE DYNAMIC FRAME SYSTEM” filed 6 Jan. 2022, which the disclosures of such are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

Embodiments of the invention generally relate to a pre-fabricated and pre-engineered framing building blocks that can be integrated in a manufacturing facility and then easily assembled and/or installed on a construction site. This is scalable and modular.

BACKGROUND OF THE INVENTION

Construction projects proceed in stages because certain aspects of the project must be completed prior to the next stage being initiated. However, the traditional stages of constructing a building can be altered with some creative thinking. In addition, creating a facility with standardize parts that are regularly assembled into different example frame s, which are then shipped to a work site as an assembled metal frame is a revolutionary thought in the construction process.

SUMMARY

In an embodiment, apparatuses, methods, and systems are discussed for an assembled frame for a structure in a building. The assembled frame for a structure in the building is formed from multiple different types of building blocks for a frame. The assembled frame for the structure in the building is formed with the multiple different types of building blocks for the assembled frame in a manufacturing facility, and then shipped as the assembled frame to a construction site. The multiple different types of individual building blocks for the frame can at least include two or more of i) metal beams/strut framework, ii) metal angle frames, iii) metal cross connects, and iv) metal mating blocks.

These and other features of the design provided herein can be better understood with reference to the drawings, description, and claims, all of which form the disclosure of this patent application.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the invention in which include many numbered and unnumbered figures that accompany the descriptions herein.

FIG. 1 illustrates an embodiment of nine separate example assembled frames on the floor of a manufacturing facility that can be shipped separately to a construction site and then rapidly coupled together to form a single cable tray frame at the construction site.

FIG. 2 illustrates an embodiment of a perspective view of four assembled frames each in a rectangular three-dimensional shape.

FIG. 3 illustrates an embodiment of a magnified view of one of the assembled frames formed with all five of the types of building blocks including some bent frames as well as a portion of another assembled frame to the left.

FIG. 4 illustrates an embodiment of a perspective view of the assembled frame of the cage formed from multiple building blocks including metal struts and metal cross-connects.

FIG. 5 illustrates the top down view of the assembled frame of the cage formed from multiple building blocks including metal struts and metal cross-connects as well as the nuts and bolts connecting to mate up the building blocks with each other.

FIG. 6 shows a front view of the assembled frame of the cage formed from multiple building blocks and then a detail cut out of how the nuts and bolts are connecting through the various holes made in the building blocks.

FIG. 7 illustrates a side view of the assembled frame of the cage formed from multiple building blocks consisting of two struts showing the large reinforced holes in the struts and two cross-connects connecting to the two struts together with the bolts and nuts attached as well as then the other holes that allow for connecting to these different building blocks at multiple orientations.

FIG. 8 illustrates an isometric view, a top view, and a front view of an example cross-connect showing a set of five holes on the left-hand side and five holes on the right hand side allowing the cross-connect to connect at multiple different orientations as well as multiple angles.

FIG. 9 illustrates an isometric view, a top view, and a front view of a metal angle frame at a 90° angle with two pairs of opposing holes on each end of the angel frame.

FIG. 10 illustrates a front view, a side view, and an isometric view of metal struts with the two larger reinforced holes for rigging holes and the multiple pairs of holes to allow the various building blocks to connect at multiple angles and orientations to the metal strut.

FIG. 11 illustrates an isometric view, a top view, a front view, and an end view of a mounting block with an example four holes to allow the mounting block to be connected to on either the front side or the back side.

While the invention is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The invention should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

DETAILED DISCUSSION

In the following description, numerous specific details are set forth, such as examples of specific data signals, named components, connections, amount of power supplies, etc., in order to provide a thorough understanding of the present invention. It will be apparent, however, to one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well known components or methods have not been described in detail but rather in a block diagram in order to avoid unnecessarily obscuring the present invention. Further specific numeric references such as first enclosure, may be made. However, the specific numeric reference should not be interpreted as a literal sequential order but rather interpreted that the first strut is different than a second strut. Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present invention.

Example apparatuses, systems, and methods for producing an assembled frame for a structure in a building are discussed.

FIG. 1 illustrates an embodiment of nine separate example assembled frames on the floor of a manufacturing facility that can be shipped separately to a construction site and then rapidly coupled together to form a single cable tray frame at the construction site. The image also shows building blocks for the straight parallel and bent/offset (e.g. snaked) sections that route some cables in the webbing of the assembled frame 100 section. The bent/offset sections and straight parallel again are part of the set of individual types of building blocks for a frame for a structure in a building. Note additional components can be connected to the frame for a structure in a building made from building blocks at various additional holes manufactured into the build block part.

The assembled frame 100 for the structure in the building is formed from multiple different types of building blocks for a frame. The assembled frame 100 for the structure in the building with the multiple different types of building blocks for the frame is formed in a manufacturing facility and then shipped to a construction site. In general, a set of multiple types of pre-fabricated and pre-engineered metal building blocks for a frame that can be integrated in a manufacturing facility into portions of a skeletal assembled frame 100 for a structure in a building, such as i) a room, ii) HVAC hanger, iii) cable tray, iv) etc. that comes to a construction site in easily shippable modular sections that are easily assembled and scalable is described. This provides for a faster delivery and construction of structural frames within a building. The concept of creating a facility with standardized parts/individual building blocks that are regularly assembled into different example frames, which are then shipped to a construction site as an assembled metal frame is a revolutionary thought in the construction process.

The limited set of different types of individual building blocks for a frame can include i) metal beams/strut framework, ii) metal angle frames, iii) metal cross connects, iv) mating blocks, v) etc. that come in standard nominal lengths/sizes.

The pre-fabricated and pre-engineered set of building blocks for a frame can be easily assembled together via nuts and bolt mating between individual building blocks. An assembled frame 100 as a standalone frame and/or an assembled frame 100 section of multiple frame sections being joined at the construction site of a final assembled frame is composed of multiple different types of building blocks for a frame. Each individual building block in the limited amount/set of building blocks in its standard shape and size is pre-engineered to be structurally sound and as such when connected together to form a larger structure the engineering does not need to be recertified when forming an assembled frame 100.

The multiple different types of building blocks for the frame are generally stored in the manufacturing facility to allow for supply chain management of parts needed to construct the assembled frame 100 while minimizing an amount of floor space and storage space needed in the manufacturing facility to facilitate building the assembled frame 100 into instances of the assembled frame 100 that have different shapes, dimensions, and functional purposes of the assembled frame 100 (e.g. cable tray, walls for a room, HVAC hangers, etc.) Thus, all of the building blocks for a frame in the set of building blocks are designed to assemble together but the resulting end product can be multiple different end products that vary in size shape and other characteristics.

Each building block for a frame has a set of holes drilled, stamped, or otherwise formed in a building block for a frame.

Next, a set of holes, for example, four holes can be aligned and located such that the assembled frame 100 can be formed from different angles when a mating connection is formed as well as the orientation of the angle frame and/or the strut can be flipped from one side to another side so that the same instance of a building block can couple up to another building block in multiple, different angles and orientations (vertically connection, horizontal connection, front side connection, flip side back side connection), where each different connection allows for a different shape/angle to be formed. This eliminates a need for the building blocks to specifically fit merely on only one side and/or in only one way. Thus, the individual building block has connections to connect on both sides of the individual building block and/or in multiple different ways. Typically, a part designed for a right side shape has to have different aligned holes than a left side shape. However, by merely flipping from one side to the other side, with an alternative set of holes also being formed into that building block, a single instance of a building block can connect up as a right side part and/or a left side part. The bolt and hole pattern formed in the building block allows for multiple ways for these building blocks to connect to each other; and thus, lots of holes (three or more) are designed into a building block versus one or two holes. This is more expensive and may require thicker metal structures to have a same structural integrity but allows for both lots of versability, a much more limited set of components needed to be stored, and extra holes for other external structures to connect to.

The multiple different types of building blocks that are produced with a set of holes aligned and located within a metal structure of a produced building block can be used such that any type of a building block can mate with another building block at 1) multiple different angles, 2) multiple different orientations or 3) a combination of both multiple different angles and multiple different orientations when forming the assembled frame 100 for the structure in the building. Thus, the building blocks for a frame such as steel beams/struts, steel cross connects, steel angles/angle frames, and mating blocks have a set of precisely located holes and dimensions of these holes to allow an assembled frame 100 from these building blocks to maintain the structural integrity even when the building blocks are mated together in two or more different orientations and/or two or more angles.

Note, the multiple different types of individual building blocks for the frame in the set can consist of two or more of i) metal beams/strut framework, ii) metal angle frames, iii) metal cross connects, iv) metal mating blocks, v) bent frames (snaking sections), etc. In an example, the set of individual building blocks for the frame includes all five of i) metal beams/strut framework, ii) metal angle frames, iii) metal cross connects, iv) metal mating blocks, v) bent frame (snaking sections), vi) etc. All of the different types of individual building blocks for a frame can be mass produced and made independent of each other.

FIG. 4 illustrates an embodiment of a perspective view of the assembled frame of the cage formed from multiple building blocks including metal struts and metal cross-connects.

Referring to the drawings an assembled frame 100 in the shape of a rectangular cage/frame made of three different types of building blocks. In an example, three different types of building blocks are 4 horizontal struts, 4 vertical angle frames, and 4 cross connects mated up to form the assembled frame 100 for a structure in a building. Each example different type of individual building block has its own drawing showing its shape, form, and example holes located in the metal structure making up that building block for framing.

FIG. 8 illustrates an isometric view, a top view, and a front view of an example cross-connect showing a set of five holes on the left-hand side and five holes on the right hand side allowing the cross-connect to connect at multiple different orientations as well as multiple angles. FIG. 8 illustrates also shows an end view of the cross-connect in the shape of essentially U.

FIG. 9 illustrates an isometric view, a top view, and a front view of a metal angle frame at a 90° angle with two pairs of opposing holes on each end of the angel frame.

FIG. 10 illustrates a front view, a side view, and an isometric view of metal struts with the two larger reinforced holes for rigging holes and the multiple pairs of holes (e.g. 14 holes) to allow the various building blocks to connect at multiple angles and orientations to the metal strut.

FIG. 11 illustrates an isometric view, a top view, a front view, and an end view of a mounting block with an example four holes to allow the mounting block to be connected to either the front side or the back side.

Each building block for framing can be a pre-formed metal section. The fabrication of each of the pre-engineered building blocks is made with a structurally sound metal material, such as steel (e.g. A36 steel), in order to be structurally sound enough to support the weight of the assembled frame 100 and its expected cables, pipes, etc. that will be supported by that assembled frame 100.

The limited set of different types of individual building blocks for a frame in a standard size, shape for framing can include i) strut framework, ii) angle frames, iii) cross connects, iv mating blocks, v) etc. that come in standard nominal lengths/sizes of, for example, 2 foot, 4 foot, 6 foot, 8 foot, and 10 foot for the i) strut framework, ii) angle frames, iii) cross connects. Unlike unistrut there is no need to cut and drill these building blocks that are already manufactured in, a standard shape and form, with multiple different connection points that are all precision cut with laser equipment and/or stamped into the structural material forming the building block. Each instance of a same type of standardized building block for framing can be essentially identical in shape and form but just a differing standard nominal length. Thus, a 2 foot metal strut frame is manufactured to be nominally the same size and shape as compared to another 2 foot metal strut frame. Some of the parts of the building blocks can be symmetrical and/or mirrored with respect to each other.

Thus, each different type of the multiple different types of building blocks for the frame is a pre-formed metal structure, has its own function, nominal shape, and is produced in multiple different standard nominal lengths.

Each component part is a pre-fabricated building block for framing can come in standard nominal lengths sizes. Thus, the pre-fabricated components, such as the angle frame, cross connect beams, struts, etc. can come in standard nominal lengths such as 2 foot, 4 foot, 5 foot, and 10 foot with pre-fabricated bolt holes, the structurally reinforced rigging holes, additional connection points, and/or markings for screws and thickness of the metal to support a weight load of the assembled frame 100 for a structure in a building (e.g. room) that is shipped to a construction site in modular sections that are easily assembled at the construction site. The thicker the metal, the more heavy-duty the project.

FIG. 2 illustrates an embodiment of a perspective view of four assembled frames each in a rectangular three-dimensional shape.

FIG. 3 illustrates an embodiment of a magnified view of one of the assembled frames formed with all five of the types of building blocks including some bent frames as well as a portion of another assembled frame to the left.

Thus, the different lengths can be assembled to make up different sized modular sections of the assembled frames 100 in a facility. For example, four 4 foot sections of struts, four 10 foot cross connect sections, and four 5 foot angle frames can be bolted together for the assembled frame 100 section to make the base for a 4 foot by 10 foot by 5 foot rectangular shaped assembled frame 100. Likewise, four 5 foot sections of struts and three 8 foot angle frames can be bolted together for the assembled frame 100 sections to make a 5 foot wide by 8 foot high triangular shaped frame. However, each side of the triangular shape could consist of, for example, three 5 foot struts connected in series to make a 15 foot wide by 8 foot high triangular shaped frame.

In an example, the hole locations made by the laser allow a building block for framing to mate up with another building block in multiple different configurations such as horizontally, or vertically, and/or at an angle, such as 45 degree angle and/or 135 degree angle. Enough precise holes are present so that all four of these possible matings can be made and still have the building blocks mate up squarely while maintaining the structural integrity and weight supporting capability of an assembled frame 100 section. An example set of four precisely located holes in a 2 by 2 arrangement can be made into an end of a building block such as a metal angle frame, a mating block, etc. With this 2 by 2 hole arrangement because merely two nuts and bolts are needed for maintaining structural integrity, then the mating could be in i) a 135 degree angle (like a back slash \), ii) a 90 degree angle (I), iii) a 45 degree angle (like a forward slash /), iv) a 180 degree angle (−−), v) etc.

Thus, the building block of the metal angle frame is produced with a set of holes aligned and located in the metal angle frame such that the metal angle frame can mate with another building block, such as a metal strut, at multiple different angles when forming the assembled frame 100 for the structure in the building. Thus, various individual building blocks have connections to connect on both sides of the individual building block and/or in multiple different ways.

The set of holes, again an example four holes can be aligned and located such that the assembled frame 100 can be formed from different angles when a mating connection is formed as well as the orientation of the angle frame and/or the strut can be flipped from one side to another side so that the same instance of a building block can couple up to another building block in multiple, different angles and orientations (vertically connection, horizontal connection, front side connection, flip side back side connection), where each different connection allowing for a different shape/angle to be formed. The hole locations made by the laser allow a building block for framing to mate up with another building block in multiple different configurations such as horizontally, or vertically, and/or at an angle, such as 45 degree angle and/or 135 degree angle.

These pre-formed metal sections of building blocks have pre-drilled bolt holes for connections to aligned bolt holes of adjoining/abutting/connecting building blocks. Bolt hole patterns in the individual building blocks for a frame can be made symmetrical and/or mirrored with respect to an adjoining building blocks for framing. A laser drilling system can create holes precisely at the distance and dimensions and precise in size and location.

The building blocks for a frame each have a standard shape and form, a set of standard sizes, and multiple connection points (e.g. holes) to allow each piece to be able to connect in multiple different ways (e.g. based on what side of the building block the next building block connects to, what set of holes are utilized, etc.) in multiple different configurations to other building blocks.

One or more of the holes in the building block can be a threaded hole in the framework, which nuts and bolts and/or screws can thread through the threaded hole in the framework. The individual building blocks for a skeletal frame for a structure in a building (e.g. room, cable trays, HVAC hangers, etc.) form the frame via fastening and torquing to the frame with nuts and bolts. The mounting holes may be tapped to receive a particular type of threaded bolt. The round holes may also be large enough to permit a bolt to be freely inserted through without binding, and bolts can be fastened in place using, for example, cage nuts.

The example mating block in the set of the building blocks for a frame a structure in a building can come in different shapes and sizes. The mating block and other building blocks for a frame can be made with sigma shaped channels so that the heads of the carriage bolts do not touch each other when the abutting and adjoining sections mate together.

The multiple different types of building blocks are constructed to secure to another building block via a nut and bolt mating, which can be torqued and inspected at the manufacturing facility and then shipped to the construction site. The individual building blocks for a skeletal frame for a structure in a building (e.g. room, cable trays, HVAC hangers, etc.) form the frame via fastening and torquing to the frame with nuts and bolts. The individual building blocks for a frame are manufactured to bolt together so there's no welding needed to join them.

The formed metal sections of some of the building blocks for a frame have channels with bolt holes predrilled into them and/or stamped into them. In the channel, predrilled bolt holes can exist for both, for example, a top cross connect beam and a bottom cross connect beam. The bolt holes of the pre-fabricated building blocks for a frame including the cross connect beams are precisely measured and inserted into each of these pre-fabricated components of the building blocks for a frame so that these components may quickly connect up at the construction site. All of the building blocks for a frame the room are designed to assemble together but the resulting end product can be multiple different end products that vary in size shape and other characteristics.

The dimensions and surfaces and connection points are made such that there is no real slop with pretty tight clearances on all of these connection points/holes so once you bolt together one building block for a frame to another building block for the frame they mate up squarely with the surfaces of the building block for framing in contact with each other. This, in essence, eliminates any need to cut or make adjustments at the construction site and/or at an assembly factory to assemble the building blocks for a frame together when forming the assembled frame 100 as well as allows a structurally strong assembled frame 100 to be built. In addition, heavy individual building blocks and/or heavy individual assembled modular sections of the skeletal frame for the structure (e.g. walls of a room, sections of HVAC hanger system, etc.) can take advantage of chain hoists in the factory and other lifting aids to assist in connecting different individual building blocks for a frame to form and assemble these modular sections of the room.

FIG. 5 illustrates the top down view of the assembled frame 100 of the cage formed from multiple building blocks including metal struts and metal cross-connects as well as the nuts and bolts connecting to mate up the building blocks with each other.

FIG. 5 also illustrates detail A that shows a close-up of the nuts and bolts and their orientation such the nuts and installing on the top holes go in first and then there's enough room to install the second set of nuts and bolts 90° relative to the top bolts.

FIG. 6 shows a front view of the assembled frame of the cage formed from multiple building blocks and then a detail cut out of how the nuts and bolts are connecting through the various holes made in the building blocks.

FIG. 7 illustrates a side view of the assembled frame of the cage formed from multiple building blocks consisting of two struts showing the large reinforced holes in the struts and two cross-connects connecting to the two struts together with the bolts and nuts attached as well as then the other holes that allow for connecting to these different building blocks at multiple orientations.

Depending upon the size of the structure (e.g. room), an entire skeletal assembled frame 100 of the cage forming the structure in the building (e.g. room) can be assembled in the factory, compared to its representation in the building information model, and then shipped to the worksite as an assembled frame 100 (e.g. integrated preassembled platform).

The set of holes in the produced building blocks for the frame with enough holes in different locations and different positions such that additional holes do not need to be drilled into the produced building block for the frame with its set of holes, which would then change its pre-engineered structural integrity qualities of the building block for the frame when assembled in the assembled frame 100.

Again, each building block type can have its own functionality. For example referencing FIG. 10, the metal beams/strut framework is produced with two or more large structurally reinforced holes that are sized and positioned for at least one of a construction hoist, such as a chain hoist, and a construction lift, such as a crane, to lift the assembled frame 100 into place at the construction site while maintaining its shape and structural integrity when being put into place at the construction site. Each section of the assembled frame 100 has one or more building blocks for a frame with the additional holes sized, positioned, and structurally reinforced in the case of rigging holes (e.g. engineered) to support the weight when a crane hoist lifts/riggings that section of the assembled frame 100 and any pipe, cables, other components already installed on the assembled frame 100 in the factory into place at the construction site. Each section can be lifted up, for example, 10 foot in the air and installed into the building at the construction site.

Next, webbing in metal studs and other building blocks can be used as a space in between the studs where plumbing and electrical wires can be routed. An example assembled frame 100 from the building blocks for a frame is an electrical cable tray frame that can be assembled and will meet all electrical Underwriter Labs requirements as well as hold the weight of assembled cables when shipped to the construction site and lifted by a crane, via the reinforced rigging holes in the metal stud building block, into place at the construction site. Another example assembled frame 100 can be a frame for a pipe run, for HVAC ductwork, etc. The assembled frame 100 for a structure in a building formed from the multiple different types of building blocks for a frame can also be a support structure for electrical power skids and enclosures. The assembled frame 100 for a structure in a building formed from the multiple different types of building blocks for a frame can also be, for example, sections of an assembled floor frame. The list of example structured assembled frames 100 for a structure in a building to be shipped to the construction site can go on and on.

Next, the assembled frame 100 for the structure in the building assembled at the manufacturing facility located away from the construction job site is constructed to be able to stand on its own when the assembled frame 100 is shipped as well as when the assembled frame 100 is lifted and put in place at the construction job site. The hole placements in the multiple different types of building blocks are located to keep an alignment of the building blocks forming the assembled frame 100 so that they are working against each other instead of with each other, which results in the assembled frame 100 being able to stand on its own and maintain its structural integrity [without ending sagging in it shape] when being lifted into place at the construction site. Note, the different building blocks are manufactured and designed to mate up squarely to keep their structural integrity and have enough structural strength to allow the assembled frame 100 to be capable of standing on its own when being shipped to the construction site. Note, the types of individual building blocks including the steel beams, steel cross connects, steel angles, and mating blocks have precisely located holes and dimensions of these holes to allow an assembled frame 100 from these building blocks to mate up squarely to maintain the structural integrity. Also, the building blocks have the ends of those parts that are constructed to lock everything together. For example, the angle of the angle frame meets up with the channels of the struts and/or cross connects to lock in. They are going to meet squarely in order to retain and create their structural integrity. This locks everything into positions so nothing can twist on the assembled frame 100 section.

Again, the types of individual building blocks can consist of steel beams, steel cross connects, steel angles, and mating blocks with precisely located holes and dimensions of these holes to allow an assembled frame 100 from these building blocks to maintain the structural integrity. These individual building blocks couple up at standard precise holes and dimensions to mate together to mate up squarely to maintain a structural integrity of the structure in a building. Also, hole placements in the building blocks are located to keep the assembled frame 100 pieces so that they're working against each other instead of with each other, which results in the stand-alone frame constructed to stand by itself and you can't easily physically push the assembled frame 100 over while standing.

Each building block for framing can use the laser drilled precise holes to allow connection and mating to other building blocks for a frame at the pre-engineered designed locations in the building blocks in order for the building blocks to assemble together squarely so that they can maintain their structural integrity and not change shape or be twisted at awkward angles when mated with bolts and torqued in place. The structural material for framing (e.g. metal—steel/iron beams) allows builders to frame—tall, durable, fire resistant (e.g. non-flammable at normal fire temperatures), galvanized/rust resistant, and structurally sound/structural integrity frames for a building structure (e.g. not easily warped, buckled, twisted or bent) when the assembled frame 100 is shipped and/or a crane lifted up to be installed as an assembled frame 100 at the construction site. Also, an assembled floor frame can be assembled with solid structural integrity to support a huge weight of the electrical cabinets, Uninterruptable power supplies, etc., and its wired cabling fully assembled.

Note, a metal material, such as A36 steel, is structurally strong enough to hold the weight of the assembled frame 100 with the additional weight of, for example, a thousand pounds of cable installed in the factory onto the assembled frame 100 and then installed in place at the construction site.

Next, the assembled frame 100 for the structure in the building is constructed in the manufacturing facility away from the construction site, checked to make sure the assembled frame 100 for the structure in the building will meet an exact dimensions (e.g. length and width) needed at the construction site via a comparison to a Building Information Model for the building being created. Thus, away from the construction site at the manufacturing facility before the creation of the assembled frame 100 for a structure in a building, the planned assembled frame 100 can be compared to the Building Information Model for the building being created to check that the dimensions of the assembled frame 100 will work as well as after the assembled frame 100 is constructed and then compared to the Building Information Model for the building being created to check that dimensions of the assembled frame 100 will work.

The different sections can easily align to each other due to the pre-engineering in order to bolt them together to form the skeletal frame for the assembled frame 100. The modular sections of the skeletal frame for a structure in a building allow frames of almost any dimension to be quickly assembled in the factory, compared to their exact dimensions and shape in a Building Information Model, and then later installed on the worksite.

Next, no welding is required and merely nut and bolt assembly so that assembly may occur in a very rapid fashion. A huge benefit of the assembled frame 100 sections for a structure in a building formed from the individual types of building blocks is the cutting down on time to build at the construction site, takes advantage of lifting devices, such as chain hoists, pneumatically powered lifting devices, forklifts, etc., present in a facility, ready availability of parts, including the types of individual building blocks for framing, in the shelves and storage stacks of parts in a facility, etc. to be assembled into the frames being made at the facility, which are then compared to a Building Information Modeling (BIM), and then shipped to the construction site, which significantly speeds up the time to complete a building project at a construction site. All of the certifications that can be made for the assembled frame 100 sections prior to being shipped are made in the factory, which also cuts down on installation time at the construction site.

Unlike standard stick build constructions of a structural frame, the vast majority of the sections of the skeletal frame making up this entire assembled frame 100 are pre-fabricated and pre-engineered in an offsite manufacturing center, in standardized nominal lengths, shapes, geometries, and components to all precisely fit together to form the assembled frame 100 so they merely need to be bolted and/or screwed together. This allows the assembled frame 100 to be built quite a bit faster with more cohesion and eliminates making cuts and/or adjustments at each mating between individual building blocks for framing.

Next, a design and manufacture of an assembled frame 100 intended to be a much bigger frame at the construction site can be broken up into multiple structures of assembled frame 100 sections for shipping purposes. The assembled frame 100 is also scalable to be sized for multiple different shipping splits in order to meet or be under (be within) maximum shipping lengths, widths, and weights allowed, and then sections of the assembled frame 100 can be joined together at the construction site.

Shipping a single assembled frame 100 with the cables that are being routed/supported in the cable tray already installed in that single assembled frame 100 for, for example, a 100 foot long cable tray is not really practical. However, assembling five 20 foot assembled sections could be practical; and thus, the five 20 foot assembled sections would be assembled in the factory and then shipped. The assembled sections could be assembled months ahead of time and then stored on floor space. Although, the assembled sections need not be assembled months ahead of time and then stored on floor space to, for example, provide just in time production of the assembled frames 100.

Each of these assembled frame 100 sections, after shipping, can later at a construction site be assembled together as sections of assembled frame 100s that are connected together. Each of these assembled frames 100 can later be bolted together directly and/or connected together with one or more additional build blocks for framing material to link and couple these sections of assembled frames 100.

In an embodiment, some small modifications can happen after shipping. This allows for virtually any sized assembled frame 100 to be 95%-100% assembled with these pre-fabricated sections and then just that little last bit of the assembled frame 100 to be custom adapted to the building at the construction site if need be. However, merely that last section needs to be tailored/customized to the exact dimensions of the assembled frame 100 for that building. The rest of the building blocks for a frame have been both pre-engineered and pre-fabricated to match in shape and connections while also easily securing with each other. This allows for virtually any sized assembled frame 100 to be assembled on site quite quickly. In most embodiments, no adjustments are needed and the assembled frames 100 from the manufacturing facility are simply installed in place at the construction site.

A scalable dynamic frame system is discussed. The scalable dynamic frame system is assembled and constructed from a set of different mass produced/standard building blocks for framing. Again, the nut and bolt assembled scalable dynamic frame can be assembled with a limited set of different types of and different sized standard building blocks for framing.

Enclosures and other equipment can be mounted to the frame via fastening and torquing to the frame with nuts and bolts and/or screws threading through a threaded hole in the framework.

Additional holes are created in individual pieces for the building blocks so other components can readily attach to these building blocks. For example, electrical bonding/grounding straps can readily be attached to an assembled frame 100 section, and inspected and certified in the factory cutting down on time to build at the construction site.

When implemented as an electrical cable tray the sections of cables installed on each section of assembled frame 100 can have electrical splices and/or quick disconnects attached to the cables so that the cables being routed and supported in the electrical cable tray in each different section can be coupled to the joining section's electrical cables at the construction site.

The storage requirements for this limited set of different types of building blocks for a frame that is scalable is a very small area compared to one or more fully assembled end products and the limited amount of building blocks for a frame can sit in a storage area until they're ready to be assembled together to form the fully assembled frame 100 end product in a factory setting and the fact that they both together and then allows them to then be disassembled for shipping and quickly reassembled back in the field. Again, the building blocks for the frame can be readily stored individually in their standard nominal lengths until assembled on the factory floor to create the frame of for example a cable tray or a cable run or even a frame for a modular power skid or something else in construction. An assembled frame 100 for parts of a building can occupy a large amount of floorspace when assembled prior to being shipped to a construction site to be installed in place at the construction site. The building blocks for the frame can be readily stored individually to allow for an easy supply chain management of parts needed to construct an assembled frame 100 of virtually infinite shapes and dimensions and functionality, while minimizing an amount of floor space and storage space needed to facilitate building all of these different types of shapes, dimensions, and functionalities of assembled frames 100.

The multiple assembled frame sections 100 can take up half of the floor space of the manufacturing facility. The different types of building blocks for a frame can occupy a very small footprint when storing the individual building blocks for framing, which can then produce virtually any sized assembled frame 100 and any shape, which is manufactured into shippable sections on an as needed basis so that huge amounts of extra floor space are not needed for a manufacturing facility to handle multiple different framing jobs.

Again, an assembled frame 100 that mates in the pre-engineered holes and meets the torquing requirements can be made, for example, 30 foot long or 100 foot long and neither assembled frame 100 needs to obtain a subsequent architectural approval on the final assembled frame because the structural integrity of the individual building blocks is not modified or compromised during the construction process.

A set of building blocks for the frame can be readily stored individually to allow for an easy supply chain management of parts needed to construct an assembled frame 100 of virtually infinite shapes, dimensions, and functionality, while minimizing an amount of floor space and storage space needed to facilitate building all of these different types of shapes, dimensions, and functionalities of assembled frames 100.

Components to be scalable to develop very large span of assembled frame 100 products as well as a diverse amount of types of frames utilizing a minimal amount of standardized mass produced building blocks for a frame (such as 12 or less, 20 or less, etc.) All of the assembled frame 100 sections (nine example assembled frames 100 are shown in FIG. 1 that vary in shape and size) can be assembled from a total of seven or less different types of building blocks for framing. Thus, a minimal amount of standardized mass produced building blocks for a frame can be connected up together in varied ways to have a virtually infinite number of shapes and sizes that the assembled frame 100 sections can be built into.

This design allows a supply chain management sourcing and assembly of a minimal amount of standardized mass produced building blocks (e.g. 12) components to build the virtually infinite number of shapes and sizes of assembled frame 100 sections versus trying to build custom assemblies with a mix of standard components and a set of custom components that need to be custom manufactured and/or cut to shape on the job site.

Again, assembly of the assembled frame 100 and subsequent shipping may occur in a very rapid fashion. Additional holes do not need to be drilled into the building block for a frame which would then change its pre-engineered structural integrity qualities of the building block when assembled into an assembled frame 100. Note, the assembled frame 100 does not need to subsequently obtain an architectural approval for that frame because the individual framing building blocks already have an architectural approval and when assembled and torqued to the requirements, and the building block for a frame has not been structurally altered or modified in the field, then the assembled frame 100 does not need to subsequently obtain an architectural approval. Again, the building blocks are manufactured and designed to mate up squarely to keep their structural integrity and that structural strength as well as being capable of standing on its own when being shipped to the construction site.

A time saver faster to assemble the building blocks with nut bolts for the frame, simply pull these individual building blocks for a frame from storage shelves and putting them together rather than having to wait on a fabrication process to make and ship custom parts and/or wait on specialty operations such as a welding process.

The assembled frame 100 sections can be built as needed because of the rapid assembly and certification process; and thus, the assembled frame 100 section will spend very little time taking up all of the available floor space in a manufacturing site causing the organization to miss out on building other jobs. Again, the individual pieces of the building blocks for a frame can be stored in bulk on shelves until an assembled frame 100 is requested to be built. As such, the assembled frame 100 from the building blocks for a frame will occupy vast areas of floorspace merely when the assembled frame 100 sections are assembled and then are certified and shipped off to the construction site. Assembled frame sections generally will not spend months at a time occupying floor space in the manufacturing facility. The fast assembly process with nuts and bolts without a need of custom made parts or specialty operations such as welding is not needed because the design of the building block allows for a just in time building approach. Naturally, structural frames for pipe runs, mechanical plumbing systems, electrical cable trays, raised floors for a room, ductwork framing for HVAC, structural framing for fire sprinklers, etc. take up a large amount of floor space due to the nature of these structures.

Additional time savings occurs when the pipes, cables, and/or other components usually carried by and supported by the assembled frame 100 are installed in the factory into the assembled frame 100. The cable tray frame that is going to be created for that electrical room is assembled by the assembling of different length selected sizes together in order to meet the size and dimensions of the building where the cable tray frame is going to be installed but this process is able to pre fabricate most of the run of the cable tray in the factory and then ship that cable tray in preassembled sections to the construction site. In addition, the pipes, cables, HVAC that would be installed at the construction site into that frame can be pre-installed onto the assembled frame 100 and any possible certification needs made at the factory and then shipped as an assembled unit in order to be mated up at the construction site.

While some specific embodiments of the invention have been shown, the invention is not to be limited to these embodiments. For example, most functions performed by electronic hardware components may be duplicated by software emulation. Thus, a software program written to accomplish those same functions may emulate the functionality of the hardware components in input-output circuitry. The type of cabinets may vary, etc. The invention is to be understood as not limited by the specific embodiments described herein, but only by scope of the appended claims.

Claims

1. An apparatus, comprising:

an assembled frame for a structure in a building formed from multiple different types of building blocks for a frame, where the assembled frame for the structure in the building is formed with the multiple different types of building blocks for the assembled frame in a manufacturing facility, and then shipped as the assembled frame to a construction site, where the multiple different types of individual building blocks for the frame consist of two or more of i) metal beams/strut framework, ii) metal angle frames, iii) metal cross connects, and iv) metal mating blocks.

2. The apparatus of claim 1, where each different type of the multiple different types of building blocks for the frame is a pre-formed metal structure, has its own function, nominal shape, and is produced in multiple different standard nominal lengths.

3. The apparatus of claim 1, where the assembled frame for the structure in the building assembled at the manufacturing facility located away from the construction job site is constructed to be able to stand on its own when the assembled frame is shipped as well as when the assembled frame is lifted and put in place at the construction job site, where hole placements in the multiple different types of building blocks are located to keep an alignment of the building blocks forming the assembled frame so that they are working against each other instead of with each other, which results in the assembled frame being able to stand on its own and maintain its structural integrity when being lifted into place at the construction site.

4. The apparatus of claim 3, where the multiple different types of building blocks are constructed to secure to another building block via a nut and bolt mating, which can be torqued and inspected at the manufacturing facility and then shipped to the construction site.

5. The apparatus of claim 1, where the building block of the metal beams/strut framework is produced with two or more large structurally reinforced holes that are sized and positioned for at least one of a construction hoist and a construction lift to lift the assembled frame into place at the construction site while maintaining its shape and structural integrity when being put into place at the construction site.

6. The apparatus of claim 1, where the assembled frame for the structure in the building is constructed in the manufacturing facility away from the construction site, checked to make sure the assembled frame for the structure in the building will meet an exact dimensions needed at the construction site via a comparison to a Building Information Model for the building being created.

7. The apparatus of claim 1, where the building block of the metal angle frame is produced with a set of holes aligned and located in the metal angle frame such that the metal angle frame can mate with another building block at multiple different angles when forming the assembled frame for the structure in the building.

8. A method for producing an assembled frame for a structure in a building, comprising:

assembling the assembled frame for the structure in the building formed from multiple different types of building blocks for a frame,

forming the assembled frame for the structure in the building with the multiple different types of building blocks for the frame in a manufacturing facility, and then shipping the assembled frame to a construction site,

storing the multiple different types of building blocks for the frame in the manufacturing facility to allow for supply chain management of parts needed to construct the assembled frame while minimizing an amount of floor space and storage space needed in the manufacturing facility to facilitate building the assembled frame into instances of the assembled frame that have different shapes, dimensions, and functional purposes of the assembled frame, and

where the assembled frame is also scalable to be sized for multiple different shipping splits in order to meet or be under maximum shipping lengths, widths, and weights allowed, and then sections of the assembled frame can be joined together at the construction site.

9. The method of claim 8, further comprising:

using the multiple different types of building blocks that are produced with a set of holes aligned and located within a metal structure of a produced building block such that a first type of building block can mate with another building block at 1) multiple different angles, 2) multiple different orientations or 3) a combination of both multiple different angles and multiple different orientations when forming the assembled frame for the structure in the building.

10. The method of claim 9, where the set of holes in the produced building blocks for the frame with enough holes in different locations and different positions such that additional holes do not need to be drilled into the produced building block for the frame with its set of holes, which would then change its pre-engineered structural integrity qualities of the building block for the frame when assembled in the assembled frame.

11. The method of claim 8, where the multiple different types of individual building blocks for the frame consist of two or more of i) metal beams/strut framework, ii) metal angle frames, iii) metal cross connects, and iv) metal mating blocks.

12. The method of claim 8, where each different type of the multiple different types of building blocks for the frame is a pre-formed metal structure, has its own function, nominal shape, and is produced in multiple different standard nominal lengths.

13. The method of claim 8, where the assembled frame for the structure in the building assembled at the manufacturing facility located away from the construction job site is constructed to be able to stand on its own when the assembled frame is shipped as well as when the assembled frame is lifted and put in place at the construction job site, where hole placements in the multiple different types of building blocks are located to keep an alignment of the building blocks forming the assembled frame so that they are working against each other instead of with each other, which results in the assembled frame being able to stand on its own and maintain its structural integrity when being lifted into place at the construction site.

14. The method of claim 8, where the multiple different types of building blocks are constructed to secure to another building block via a nut and bolt mating, which can be torqued and inspected at the manufacturing facility and then shipped to the construction site.

15. The method of claim 11, where the building block of the metal beams/strut framework is produced with two or more large structurally reinforced holes that are sized and positioned for at least one of a construction hoist and a construction lift to lift the assembled frame into place at the construction site while maintaining its shape and structural integrity when being put into place at the construction site.

16. The method of claim 8, where the assembled frame for the structure in the building is constructed in the manufacturing facility away from the construction site, checked to make sure the assembled frame for the structure in the building will meet an exact dimensions needed at the construction site via a comparison to a Building Information Model for the building being created.

17. The method of claim 11, where the building block of the metal angle frame is produced with a set of holes aligned and located in the metal angle frame such that the metal angle frame can mate with another building block at multiple different angles when forming the assembled frame for the structure in the building.