Modified foam wall structures with high racking strength and methods for their manufacture

A foam wall structure comprising:

• (a) frame members 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 comprising polyisocyanurate foam or polystyrene foam 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;
• (c) a polyurethane foam layer disposed within the cavity and on a surface of the first member, the second member, and the connecting members, the polyurethane foam layer being adhered to the foam panel and having a thickness extending from the rear surface of the foam panel to a position intermediate the front frame surface and the rear frame surface so that a gap is formed within the frame between a rear surface of the foam layer and the rear frame surface, and
• (d) a cured structural adhesive, which is not a foam, that is disposed in at least one of:
• (i) an aperture located within the polyurethane foam layer, and
• (ii) an aperture located between the polyurethane foam layer and at least one of the first member, the second member, and one or more of the connecting members,
• wherein the cured structural adhesive is the cured product of a high solids-containing chemically-curing polymeric structural adhesive composition, and
• wherein the cured structural adhesive is disposed in the aperture such that the cured structural adhesive is exposed to the gap.