Prefabricated Wall Assembly Having An Insulating Foam Layer
First Claim
1. A prefabricated wall assembly for receiving an exterior covering of a building, said prefabricated wall assembly comprising:
- a frame assembly having a top member, a bottom member opposite said top member, and a plurality of vertical members coupled to and extending between said top and bottom members with said frame assembly having an interior side and an exterior side opposite said interior side; and
an insulating foam layer disposed between said plurality of vertical members of said frame assembly and extending from said exterior side of said frame assembly;
wherein said insulating foam layer terminates in a plurality of integral ribs opposite said frame assembly with an exterior surface of said insulating foam layer presented between said plurality of ribs and with said plurality of ribs spacing the exterior covering from said exterior surface of said insulating foam layer to allow airflow and drainage between said prefabricated wall assembly and the exterior covering.
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Accused Products
Abstract
A prefabricated wall assembly receives an exterior covering of a building. The prefabricated wall assembly includes a frame assembly and an insulating foam layer. The frame assembly includes a top member, a bottom member opposite the top member, and a plurality of vertical members coupled to and extending between the top and bottom members. The frame assembly also has an interior side and an exterior side opposite the interior side. The insulating foam layer is disposed between the plurality of vertical members of the frame assembly and also extends from the exterior side of the frame assembly terminating in a plurality of integral ribs. An exterior surface of the insulating foam layer is presented between the plurality of ribs. The ribs space the exterior covering from the exterior surface of the insulating foam layer for allowing airflow and drainage between the prefabricated wall assembly and the exterior covering.
74 Citations
19 Claims
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1. A prefabricated wall assembly for receiving an exterior covering of a building, said prefabricated wall assembly comprising:
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a frame assembly having a top member, a bottom member opposite said top member, and a plurality of vertical members coupled to and extending between said top and bottom members with said frame assembly having an interior side and an exterior side opposite said interior side; and an insulating foam layer disposed between said plurality of vertical members of said frame assembly and extending from said exterior side of said frame assembly; wherein said insulating foam layer terminates in a plurality of integral ribs opposite said frame assembly with an exterior surface of said insulating foam layer presented between said plurality of ribs and with said plurality of ribs spacing the exterior covering from said exterior surface of said insulating foam layer to allow airflow and drainage between said prefabricated wall assembly and the exterior covering. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method of manufacturing a prefabricated wall assembly comprising a frame assembly and an insulating layer extending from the frame assembly with a plurality of ribs integral with the insulating layer and extending from the insulating layer for spacing an exterior covering from the insulating material to allow airflow and drainage between the prefabricated wall assembly and the exterior covering
providing the frame assembly with a plurality of vertical members coupled between a top member and a bottom member; -
positioning the frame assembly adjacent a mold such that a cavity is defined between a surface of the mold and an exterior surface of the vertical members; applying a foam into the cavities defined by the mold and between the vertical members; curing the foam to form the insulating layer, which results in the formation of the prefabricated wall assembly; and demolding the prefabricated wall assembly from the mold. - View Dependent Claims (15, 16, 17, 18, 19)
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Specification