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US 11,377,850 B2Granted
Foam wall structures with high shear strength and methods for the manufacture thereof
AssigneeCovestro LLC
InventorsDavid M. Baily, James L. Lambach, Michael F. Palmosina, II
Life of this patent
Estimating the term…
Abstract
Wall structures and methods of manufacturing wall structures are described. The wall structures include a frame, a foam panel attached to the frame, a brace disposed in a cavity defined by the frame, and a foam layer. The wall structures can impart a high wall racking strength and good thermal performance through the combination of the foam layer, brace, and the foam panels.
Claims20
A wall structure comprising:
- (a) a frame comprising:
- (i) a first member;
- (ii) a second member spaced apart from the first member;
- and
- (iii) connecting members extending between the first member and the second member, wherein the first member, the second member, and the connecting members each comprise a front surface and a rear surface that form a front frame surface and a rear frame surface;
- (b) a foam panel attached to the front frame surface, wherein:
- (i) the foam panel overlies the front frame surface;
- and
- (ii) the foam panel, the first member, the second member, and the connecting members define a cavity within the frame;
- (c) a brace disposed within the cavity and fastened to the frame with one or more mechanical fasteners, the brace comprising:
- (i) a plurality of elongated brace members comprising a front brace member surface and a rear brace member surface that form a front brace surface facing the foam panel and a rear brace surface facing away from the foam panel, wherein at least one elongated brace member is disposed in the cavity such that a side thereof is substantially parallel to and in contact with the first member or the second member and at least one elongated brace member is disposed in the cavity such that a side thereof is substantially parallel to and in contact with a connecting member;
- and
- (ii) a connector connecting an end of one brace member to an end of another brace member;
- and
- (d) a foam layer disposed within the cavity, wherein the foam layer adheres to the foam panel and the brace.
12 more elements
A wall structure comprising:
- (a) a frame comprising:
- (i) a first member;
- (ii) a second member spaced apart from the first member;
- and
- (iii) connecting members extending between the first member and the second member, wherein the first member, the second member, and the connecting members each comprise a front surface and a rear surface that form a front frame surface and a rear frame surface;
- (b) a foam panel attached to the front frame surface, wherein:
- (i) the foam panel overlies the front frame surface;
- and
- (ii) the foam panel, the first member, the second member, and the connecting members define a cavity within the frame;
- (c) a brace disposed within the cavity and fastened to the frame, the brace comprising:
- (i) a plurality of elongated brace members comprising a front brace member surface and a rear brace member surface that form a front brace surface facing the foam panel and a rear brace surface facing away from the foam panel, wherein at least one elongated brace member is disposed in the cavity such that a side thereof is substantially parallel to and in contact with the first member or the second member and at least one elongated brace member is disposed in the cavity such that a side thereof is substantially parallel to and in contact with a connecting member;
- and
- (ii) a lateral load bearing connector connecting an end of one brace member to an end of another brace member;
- and
- (d) a foam layer disposed within the cavity, wherein the foam layer adheres to the foam panel and the brace.
12 more elements
Dependencies are inferred from the claim text.