Patent · US10415244B2 · B2 · US

Methods for manufacturing pre-fabricated insulated foam wall structures with high racking strength and related pre-fabricated wall structures

(11) Publication number

US10415244B2

(21) Application number

15/622,684

(22) Filing date

2017-06-14

(30) Priority date

2017-06-14

(43) Publication date

2019-09-17

(45) Date of grant

2019-09-17

(51) IPC

E04B 1/14; E04C 2/292; B29C 44/12; B29C 44/18; B29C 44/34; E04C 2/20; E04C 2/296; E04C 2/38

(52) CPC

E04C Structural elements; building materials: 2/292, 2/205, 2/296, 2/38
B29C Shaping or joining of plastics; shaping of material in a plastic state, not otherwise provided for; after-treatment of the shaped products, e.g. repairing: 44/1285, 44/186, 44/188, 44/3403
B29K Indexing scheme associated with subclasses B29B, B29C or B29D, relating to moulding materials or to materials for {moulds, } reinforcements, fillers or preformed parts, e.g. inserts: 2075/00, 2625/06, 2675/00, 2995/0063
B29L Indexing scheme associated with subclass B29C, relating to particular articles: 2031/776
B32B Layered products, i.e. products built-up of strata of flat or non-flat, e.g. cellular or honeycomb, form: 15/046, 15/085, 15/10, 15/14, 15/20, 21/047, 21/08, 21/10, 2255/02, 2255/20, 2255/26, 2260/021, 2260/046, 2262/04, 2262/101, 2266/0214, 2266/0228, 2266/0278, 2266/0285, 2307/302, 2307/50, 2307/54, 2307/72, 2307/7246, 2307/7265, 2607/00, 27/065, 27/08, 27/12, 27/32, 3/08, 3/18, 5/022, 5/18, 5/20, 5/245, 5/26, 5/32, 7/08, 7/12
E04B General building constructions; walls, e.g. partitions; roofs; floors; ceilings; insulation or other protection of buildings: 1/14

(73) Assignee

Covestro LLC

(72) Inventors

Eric C. Giles; James L. Lambach; David M. Baily

(54) Title

Methods for manufacturing pre-fabricated insulated foam wall structures with high racking strength and related pre-fabricated wall structures

(57) Abstract

Methods of manufacturing wall structures having high racking strength are described in this specification. The methods include spray applying a foam-forming composition into a cavity of a wall structure, wherein the wall structure is disposed in a climate-controlled spray application station and allowing the foam-forming material to expand within at least a portion of the cavity to form a foam layer deposited in the cavity. In the methods, the foam layer is formed in-situ during the manufacturing method, and the density of the foam layer is selected and the relative humidity and dew point of the air in the climate-controlled spray application station throughout the spray applying is selected so that the wall structure has a racking strength of at least 500 pounds per linear foot.

Full text

View on Google Patents

Claims (26)

A method of manufacturing a high racking strength pre-fabricated insulated wall structure comprising: (a) spray applying a polyurethane foam-forming composition into a cavity of a wall structure, wherein the wall structure comprises: 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 the front frame surface and a rear frame surface; and iv) a foam panel attached to the front frame surface, such that foam panel, the first member, the second member, and the connecting members define the cavity within the frame; and (b) allowing the polyurethane foam-forming composition to expand within at least a portion of the cavity to form a polyurethane foam layer deposited in the cavity, wherein the polyurethane foam layer is formed in-situ during the manufacturing method, and wherein the density of the polyurethane foam layer is 3.0 to 4.0 lb/ft 3 when measured according to ASTM D1622-08 and the wall structure is disposed in a climate-controlled spray application station throughout the spray applying wherein the relative humidity and dew point of the air in the climate-controlled spray application station is controlled throughout the spray applying so that the wall structure has a racking strength of at least 500 pounds per linear foot (2224 N).
The method of claim 1, wherein the method does not include attaching a wood panel, a plywood panel, an oriented strand panel, a fibrous structural panel, a gypsum panel, or a SIS to a front surface of the foam panel or a rear surface of the foam panel between the foam panel and the front frame surface.
The method of claim 1, wherein the relative humidity of the air in the climate-controlled spray application station throughout the spray applying is less than 75% and the dew point of the air in the climate-controlled spray application station throughout the spray applying is no more than 70° F.
The method of claim 3, wherein the dew point of the air is maintained at 20° F. to 30° F. throughout the spray application.
The method of claim 1, wherein the racking strength of the wall structure is at least 600 pounds per linear foot (2669 N).
The method of claim 5, wherein the racking strength of the wall structure is at least 900 pounds per linear foot (4003 N).
The method of claim 1, wherein the polyurethane foam layer comprises a thickness extending from the rear surface of the first foam panel to a position intermediate the front frame surface and the rear frame surface such that a gap is formed within the frame between a rear surface of the foam layer and the rear frame surface.
The method of claim 1, wherein the foam panel comprises a polyiso panel, an expanded polystyrene panel, or an extruded polystyrene panel.
The method of claim 8, wherein the foam panel comprises a polyiso panel comprising a polyisocyanurate foam layer and a facer material attached to a front face and a rear face of the polyisocyanurate foam layer.
The method of claim 9, wherein the facer material attached to the rear face comprises a coated glass fiber.
A method of manufacturing a high strength pre-fabricated insulated wall structure comprising: (a) spray applying a polyurethane foam-forming composition into a cavity of a wall structure that is disposed in a climate-controlled spray application station, wherein the wall structure comprises: 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 the front frame surface and a rear frame surface; and iv) a foam panel attached to the front frame surface, such that foam panel, the first member, the second member, and the connecting members define the cavity within the frame; and (b) allowing the polyurethane foam-forming composition to expand within at least a portion of the cavity to form a polyurethane foam layer deposited in the cavity, wherein the density of the polyurethane foam layer is 2.8 to 4.0 lb/ft 3 when measured according to ASTM D1622-08 and the relative humidity of the air in the climate-controlled spray application station throughout the spray applying is less than 75% and the dew point of the air in the climate-controlled spray application station throughout the spray applying is less than 75° F. (23.9° C.).
The method of claim 11, wherein the method does not include attaching a wood panel, plywood panel, or an oriented strand board panel to one or more of a front surface of the foam panel or a rear surface of the foam panel.
The method of claim 11, wherein the density of the polyurethane foam layer is 3.0 to 4.0 lb/ft 3.
The method of claim 11, wherein the dew point of the air is maintained at 20° F. to 30° F. throughout the spray application.
The method of claim 11, wherein the racking strength of the wall structure is at least 500 pounds per linear foot.
The method of claim 15, wherein the racking strength of the wall structure is at least 900 pounds per linear foot.
The method of claim 11, wherein the polyurethane foam layer comprises a thickness extending from the rear surface of the first foam panel to a position intermediate the front frame surface and the rear frame surface such that a gap is formed within the frame between a rear surface of the foam layer and the rear frame surface.
The method of claim 11, wherein the foam panel comprises a polyiso panel, an expanded polystyrene panel, or an extruded polystyrene panel.
The method of claim 18, wherein the foam panel comprises a polyiso panel comprising a polyisocyanurate foam layer and a facer material attached to a front face and a rear face of the polyisocyanurate foam layer.
The method of claim 19, wherein the facer material attached to the rear face comprises a coated glass fiber facer material comprises coated glass fibers.
The method of claim 3, wherein the temperature of the air in the climate-controlled spray application station throughout the spray applying is 60° F. to 80° F.
The method of claim 4, wherein the temperature of the air in the climate-controlled spray application station throughout the spray applying is 60° F. to 80° F.
The method of claim 16, wherein the temperature of the air in the climate-controlled spray application station throughout the spray applying is 60° F. to 80° F.
The method of claim 14, wherein the temperature of the air in the climate-controlled spray application station throughout the spray applying is 60° F. to 80° F.
The method of claim 21, wherein the temperature of the polyurethane foam-forming composition during the spray applying is 120° F. to 128° F.
The method of claim 23, wherein the temperature of the polyurethane foam-forming composition during the spray applying is 120° F. to 128° F.

Description

The present invention relates to methods for making pre-fabricated insulated wall structures with high racking strength, as well as the wall structures made by such methods. The methods can provide high strength pre-fabricated wall structures through the use of foam panels that have relatively low fastener pull-out strength as compared to wood panels, plywood panels, and oriented strand board panels (OSBs) and thus do not require the use of such wood panels, plywood panels or OSBs.

Insulated wall panels provide thermal insulation for residential homes and buildings. A wall panel's R-value reflects its ability to impede heat flow. The greater the ability to impede heat flow, the higher the R-value. Over the years, insulation standards have become stricter, requiring higher R-values and continuous insulation on the exterior side of insulated walls. The current market solutions to these stricter requirements are typically (1) pre-fabricated wall panels that incorporate insulation at the construction site, and (2) Structural Insulated Panels (SIPs).

The pre-fabricated wall panel that incorporates insulation at the construction site is the more widely adopted solution in the market. However, this solution requires a separate sub-contractor for on-site installation with fiberglass batting, which is known to have suboptimal R-values. Fiberglass is not an air barrier and allows for air intrusion, thus increasing the probability of condensation and mold growth within wall systems.

Citations (67)

US4443988A
US4471591A
US4671038A
US4765105A
US4786547A
US4856244A
US5389167A
US5353560A
US5950386A
US5950389A
WO1999014442A1
US6085479A
US5953883A
WO1999029978A1
US5979131A
US6613425B2
US6205729B1
US20040016194A1
US6408594B1
US6314695B1
US6308491B1
US6481172B1
US6854218B2
US6951079B2
US6332304B1
US6438915B1
US7036284B1
US20040200171A1
US8065846B2
US20050055973A1
US7168216B2
US7127856B2
US7127858B2
US20050106360A1
US20050247021A1
IE20050080A1
US20090098357A1
WO2009006441A2
US8635778B1
US8397465B2
US8397387B2
US20100011701A1
US8365497B2
US8033065B2
US20120096785A1
US8458983B2
US20110214374A1
US20110173911A1
US20120011792A1
US20120028563A1
US20130312350A1
US8959862B1
US20120240501A1
US20120247040A1
US20140115991A1
US20130104480A1
US20130305643A1
US20150140243A1
US20150111001A1
US8925270B2
US8844243B1
US20140265027A1
US20150093535A1
US20160326740A1
DE202014004695U1
US20180202159A1
US20180187417A1

Record as JSON

{
  "publication_number": "US10415244B2",
  "country": "US",
  "kind": "B2",
  "title": "Methods for manufacturing pre-fabricated insulated foam wall structures with high racking strength and related pre-fabricated wall structures",
  "abstract": "Methods of manufacturing wall structures having high racking strength are described in this specification. The methods include spray applying a foam-forming composition into a cavity of a wall structure, wherein the wall structure is disposed in a climate-controlled spray application station and allowing the foam-forming material to expand within at least a portion of the cavity to form a foam layer deposited in the cavity. In the methods, the foam layer is formed in-situ during the manufacturing method, and the density of the foam layer is selected and the relative humidity and dew point of the air in the climate-controlled spray application station throughout the spray applying is selected so that the wall structure has a racking strength of at least 500 pounds per linear foot.",
  "claims": [
    "1. A method of manufacturing a high racking strength pre-fabricated insulated wall structure comprising: (a) spray applying a polyurethane foam-forming composition into a cavity of a wall structure, wherein the wall structure comprises: 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 the front frame surface and a rear frame surface; and iv) a foam panel attached to the front frame surface, such that foam panel, the first member, the second member, and the connecting members define the cavity within the frame; and (b) allowing the polyurethane foam-forming composition to expand within at least a portion of the cavity to form a polyurethane foam layer deposited in the cavity, wherein the polyurethane foam layer is formed in-situ during the manufacturing method, and wherein the density of the polyurethane foam layer is 3.0 to 4.0 lb/ft 3 when measured according to ASTM D1622-08 and the wall structure is disposed in a climate-controlled spray application station throughout the spray applying wherein the relative humidity and dew point of the air in the climate-controlled spray application station is controlled throughout the spray applying so that the wall structure has a racking strength of at least 500 pounds per linear foot (2224 N).",
    "2. The method of claim 1, wherein the method does not include attaching a wood panel, a plywood panel, an oriented strand panel, a fibrous structural panel, a gypsum panel, or a SIS to a front surface of the foam panel or a rear surface of the foam panel between the foam panel and the front frame surface.",
    "3. The method of claim 1, wherein the relative humidity of the air in the climate-controlled spray application station throughout the spray applying is less than 75% and the dew point of the air in the climate-controlled spray application station throughout the spray applying is no more than 70° F.",
    "4. The method of claim 3, wherein the dew point of the air is maintained at 20° F. to 30° F. throughout the spray application.",
    "5. The method of claim 1, wherein the racking strength of the wall structure is at least 600 pounds per linear foot (2669 N).",
    "6. The method of claim 5, wherein the racking strength of the wall structure is at least 900 pounds per linear foot (4003 N).",
    "7. The method of claim 1, wherein the polyurethane foam layer comprises a thickness extending from the rear surface of the first foam panel to a position intermediate the front frame surface and the rear frame surface such that a gap is formed within the frame between a rear surface of the foam layer and the rear frame surface.",
    "8. The method of claim 1, wherein the foam panel comprises a polyiso panel, an expanded polystyrene panel, or an extruded polystyrene panel.",
    "9. The method of claim 8, wherein the foam panel comprises a polyiso panel comprising a polyisocyanurate foam layer and a facer material attached to a front face and a rear face of the polyisocyanurate foam layer.",
    "10. The method of claim 9, wherein the facer material attached to the rear face comprises a coated glass fiber.",
    "11. A method of manufacturing a high strength pre-fabricated insulated wall structure comprising: (a) spray applying a polyurethane foam-forming composition into a cavity of a wall structure that is disposed in a climate-controlled spray application station, wherein the wall structure comprises: 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 the front frame surface and a rear frame surface; and iv) a foam panel attached to the front frame surface, such that foam panel, the first member, the second member, and the connecting members define the cavity within the frame; and (b) allowing the polyurethane foam-forming composition to expand within at least a portion of the cavity to form a polyurethane foam layer deposited in the cavity, wherein the density of the polyurethane foam layer is 2.8 to 4.0 lb/ft 3 when measured according to ASTM D1622-08 and the relative humidity of the air in the climate-controlled spray application station throughout the spray applying is less than 75% and the dew point of the air in the climate-controlled spray application station throughout the spray applying is less than 75° F. (23.9° C.).",
    "12. The method of claim 11, wherein the method does not include attaching a wood panel, plywood panel, or an oriented strand board panel to one or more of a front surface of the foam panel or a rear surface of the foam panel.",
    "13. The method of claim 11, wherein the density of the polyurethane foam layer is 3.0 to 4.0 lb/ft 3.",
    "14. The method of claim 11, wherein the dew point of the air is maintained at 20° F. to 30° F. throughout the spray application.",
    "15. The method of claim 11, wherein the racking strength of the wall structure is at least 500 pounds per linear foot.",
    "16. The method of claim 15, wherein the racking strength of the wall structure is at least 900 pounds per linear foot.",
    "17. The method of claim 11, wherein the polyurethane foam layer comprises a thickness extending from the rear surface of the first foam panel to a position intermediate the front frame surface and the rear frame surface such that a gap is formed within the frame between a rear surface of the foam layer and the rear frame surface.",
    "18. The method of claim 11, wherein the foam panel comprises a polyiso panel, an expanded polystyrene panel, or an extruded polystyrene panel.",
    "19. The method of claim 18, wherein the foam panel comprises a polyiso panel comprising a polyisocyanurate foam layer and a facer material attached to a front face and a rear face of the polyisocyanurate foam layer.",
    "20. The method of claim 19, wherein the facer material attached to the rear face comprises a coated glass fiber facer material comprises coated glass fibers.",
    "21. The method of claim 3, wherein the temperature of the air in the climate-controlled spray application station throughout the spray applying is 60° F. to 80° F.",
    "22. The method of claim 4, wherein the temperature of the air in the climate-controlled spray application station throughout the spray applying is 60° F. to 80° F.",
    "23. The method of claim 16, wherein the temperature of the air in the climate-controlled spray application station throughout the spray applying is 60° F. to 80° F.",
    "24. The method of claim 14, wherein the temperature of the air in the climate-controlled spray application station throughout the spray applying is 60° F. to 80° F.",
    "25. The method of claim 21, wherein the temperature of the polyurethane foam-forming composition during the spray applying is 120° F. to 128° F.",
    "26. The method of claim 23, wherein the temperature of the polyurethane foam-forming composition during the spray applying is 120° F. to 128° F."
  ],
  "description_excerpt": "The present invention relates to methods for making pre-fabricated insulated wall structures with high racking strength, as well as the wall structures made by such methods. The methods can provide high strength pre-fabricated wall structures through the use of foam panels that have relatively low fastener pull-out strength as compared to wood panels, plywood panels, and oriented strand board panels (OSBs) and thus do not require the use of such wood panels, plywood panels or OSBs.\n\nInsulated wall panels provide thermal insulation for residential homes and buildings. A wall panel's R-value reflects its ability to impede heat flow. The greater the ability to impede heat flow, the higher the R-value. Over the years, insulation standards have become stricter, requiring higher R-values and continuous insulation on the exterior side of insulated walls. The current market solutions to these stricter requirements are typically (1) pre-fabricated wall panels that incorporate insulation at the construction site, and (2) Structural Insulated Panels (SIPs).\n\nThe pre-fabricated wall panel that incorporates insulation at the construction site is the more widely adopted solution in the market. However, this solution requires a separate sub-contractor for on-site installation with fiberglass batting, which is known to have suboptimal R-values. Fiberglass is not an air barrier and allows for air intrusion, thus increasing the probability of condensation and mold growth within wall systems.",
  "cpc": [
    "E04C 2/292",
    "B29C 44/1285",
    "B29C 44/186",
    "B29C 44/188",
    "B29C 44/3403",
    "B29K 2075/00",
    "B29K 2625/06",
    "B29K 2675/00",
    "B29K 2995/0063",
    "B29L 2031/776",
    "B32B 15/046",
    "B32B 15/085",
    "B32B 15/10",
    "B32B 15/14",
    "B32B 15/20",
    "B32B 21/047",
    "B32B 21/08",
    "B32B 21/10",
    "B32B 2255/02",
    "B32B 2255/20",
    "B32B 2255/26",
    "B32B 2260/021",
    "B32B 2260/046",
    "B32B 2262/04",
    "B32B 2262/101",
    "B32B 2266/0214",
    "B32B 2266/0228",
    "B32B 2266/0278",
    "B32B 2266/0285",
    "B32B 2307/302",
    "B32B 2307/50",
    "B32B 2307/54",
    "B32B 2307/72",
    "B32B 2307/7246",
    "B32B 2307/7265",
    "B32B 2607/00",
    "B32B 27/065",
    "B32B 27/08",
    "B32B 27/12",
    "B32B 27/32",
    "B32B 3/08",
    "B32B 3/18",
    "B32B 5/022",
    "B32B 5/18",
    "B32B 5/20",
    "B32B 5/245",
    "B32B 5/26",
    "B32B 5/32",
    "B32B 7/08",
    "B32B 7/12",
    "E04B 1/14",
    "E04C 2/205",
    "E04C 2/296",
    "E04C 2/38"
  ],
  "ipc": [
    "E04B 1/14",
    "E04C 2/292",
    "B29C 44/12",
    "B29C 44/18",
    "B29C 44/34",
    "E04C 2/20",
    "E04C 2/296",
    "E04C 2/38"
  ],
  "assignees": [
    "Covestro LLC"
  ],
  "inventors": [
    "Eric C. Giles",
    "James L. Lambach",
    "David M. Baily"
  ],
  "filing_date": "2017-06-14",
  "publication_date": "2019-09-17",
  "grant_date": "2019-09-17",
  "priority_date": "2017-06-14",
  "application_number": "US-201715622684-A",
  "family_id": "62909588",
  "cited_by_count": 14,
  "citations": [
    "US4443988A",
    "US4471591A",
    "US4671038A",
    "US4765105A",
    "US4786547A",
    "US4856244A",
    "US5389167A",
    "US5353560A",
    "US5950386A",
    "US5950389A",
    "WO1999014442A1",
    "US6085479A",
    "US5953883A",
    "WO1999029978A1",
    "US5979131A",
    "US6613425B2",
    "US6205729B1",
    "US20040016194A1",
    "US6408594B1",
    "US6314695B1",
    "US6308491B1",
    "US6481172B1",
    "US6854218B2",
    "US6951079B2",
    "US6332304B1",
    "US6438915B1",
    "US7036284B1",
    "US20040200171A1",
    "US8065846B2",
    "US20050055973A1",
    "US7168216B2",
    "US7127856B2",
    "US7127858B2",
    "US20050106360A1",
    "US20050247021A1",
    "IE20050080A1",
    "US20090098357A1",
    "WO2009006441A2",
    "US8635778B1",
    "US8397465B2",
    "US8397387B2",
    "US20100011701A1",
    "US8365497B2",
    "US8033065B2",
    "US20120096785A1",
    "US8458983B2",
    "US20110214374A1",
    "US20110173911A1",
    "US20120011792A1",
    "US20120028563A1",
    "US20130312350A1",
    "US8959862B1",
    "US20120240501A1",
    "US20120247040A1",
    "US20140115991A1",
    "US20130104480A1",
    "US20130305643A1",
    "US20150140243A1",
    "US20150111001A1",
    "US8925270B2",
    "US8844243B1",
    "US20140265027A1",
    "US20150093535A1",
    "US20160326740A1",
    "DE202014004695U1",
    "US20180202159A1",
    "US20180187417A1"
  ]
}

Record 2,574 of 8,000 in Patents full text (MLC-0201). Request the full dataset.