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US 11,414,862 B2Granted
Foam wall structures and methods for their manufacture
AssigneeCovestro LLC
InventorsJames L. Lambach, Michael F. Palmosina, II
Life of this patent
Estimating the term…
Abstract
Foam wall structures and methods for making them are described. The wall structures include a frame, a mesh mechanically fastened to a front surface of the frame, a foam panel at least partially abutting and overlying the mesh, and a foam layer disposed in a cavity defined by the frame, the mesh, and the foam panel. Buildings that include such wall structures are also described.
Claims20
A foam 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 mesh mechanically fastened to the front frame surface, wherein the mesh overlies and abuts the front frame surface;
- (c) a foam panel comprising a facer on at least a rear face of a core foam layer, wherein the facer on the rear face of the core foam layer abuts and overlies the mesh, wherein the foam panel, the mesh, the first member, the second member, and the connecting members define a cavity;
- and
- (d) a foam layer disposed within the cavity, wherein the foam layer penetrates the mesh and adheres to the foam panel.
6 more elements
A method for manufacturing a wall structure, comprising:
- (a) mechanically fastening a mesh to a front surface of a frame, wherein the front frame surface is formed by a front surface of a first member, a front surface of a second member that is spaced apart from the first member, and a front surface of connecting members extending between the first member and the second member, so that the mesh overlies and abuts the front frame surface;
- (b) orienting a foam panel so as to abut and overlie the mesh so that the foam panel, the mesh, the first member, the second member, and the connecting members define a cavity, wherein the foam panel comprises a facer on at least a rear face of a core foam layer, wherein the facer on the rear face of the core foam layer abuts and overlies the mesh;
- and
- (c) depositing a foam-forming material into the cavity so that the foam-forming material forms a foam layer that penetrates the mesh and adheres to a rear surface of the foam panel.
1 more element
A building comprising:
- (1) a first 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 mesh mechanically fastened to the front frame surface, wherein the mesh overlies and abuts the front frame surface;
- (c) a foam panel that overlies the mesh, wherein the foam panel, the mesh, the first member, the second member, and the connecting members define a cavity, wherein the foam panel comprises a facer on at least a rear face of a core foam layer, wherein the facer on the rear face of the core foam layer abuts and overlies the mesh;
- and
- (d) a foam layer disposed within the cavity, wherein the foam layer penetrates the mesh and adheres to the foam panel;
- and
- (2) a second wall structure disposed adjacent to the first wall structure, wherein
- (i) the second wall structure does not include a mesh fastened to a front frame surface, and
- (ii) the difference in the thickness of the first wall structure and the second wall structure is no more than 0.2 inch (5.08 millimeters).
11 more elements
Dependencies are inferred from the claim text.