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US 11,718,989 B2Granted
Modified foam wall structures with high racking strength and methods for their manufacture
AssigneeCovestro LLC
InventorsDavid M. Baily, James L. Lambach, Michael F. Palmosina, II
Life of this patent
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Abstract
Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.
Claims17
A method for modifying 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 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;
- and
- (c) a spray-applied polyurethane foam layer disposed within the cavity and on a surface of the first member, the second member, and the connecting members and adhered to the foam panel,
- wherein the method comprises depositing a high solids-containing, chemically-curing, and non-foaming liquid polymeric structural adhesive composition into at least one of (A) an aperture located within the spray-applied polyurethane foam layer, and (B) an aperture located between the spray-applied polyurethane foam layer and at least one of the frame members.
9 more elements
Dependencies are inferred from the claim text.