Prefabricated Wall Assembly Having An Outer Foam Layer

• US 20140115989A1
• Filed: 06/15/2012
• Published: 05/01/2014
• Est. Priority Date: 06/17/2011
• Status: Active Grant

• Current Assignee: BASF SE
• Original Assignee: BASF SE
• Inventors: Drewery, Michael, Sievers, Michael J., McNulty, Michael J., Davenport, Rick, Poma, Mary, Fox, Paul J., Swanson, Colby A.
• Granted Patent: US 9,702,152 B2
• Time in Patent Office: Days
• US Class Current: 52/302.1
• CPC Class Codes: E04B 2/02 built-up from layers of building elements
• CPC Class Codes: E04C 2/386 with a frame of unreconstituted or laminated wood
• CPC Class Codes: E04F 13/0869 having conduits for fluids
• CPC Class Codes: Y10T 29/49623 Static structure, e.g., a building component

Abstract

A prefabricated wall assembly receives an exterior covering of a building. The prefabricated wall assembly comprises a frame assembly and an outer foam layer. The outer foam layer is coupled to the frame assembly. The outer foam layer extends from the frame assembly to an exterior surface of the outer foam layer. The exterior surface of the outer foam layer is configured to receive the exterior covering of the building. The outer foam layer comprises a plurality of particles and a binder that define a plurality of pathways. The pathways extend vertically through the prefabricated wall assembly from the top member to the bottom member of the frame assembly for allowing airflow and drainage between the frame assembly and the exterior covering.

Claims

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 outer foam layer coupled to said frame assembly and extending from said exterior side of said frame assembly and terminating at an exterior surface of said outer foam layer, with said exterior surface of said outer foam layer configured to receive the exterior covering of the building;

wherein said outer foam layer comprises a plurality of particles and a binder that define a plurality of pathways extending vertically through said prefabricated wall assembly from said top member to said bottom member of said frame assembly for allowing airflow and drainage between said frame assembly and the exterior covering.

2. A prefabricated wall assembly as set forth in claim 1 further comprising an intermediate substrate disposed between said outer foam layer and said frame assembly with said outer foam layer bonded to said intermediate substrate and said intermediate substrate coupled to said frame assembly for coupling said outer foam layer to said frame assembly.

3. A prefabricated wall assembly as set forth in claim 2 further comprising an inner foam layer disposed between and bonded to said vertical members of said frame assembly and bonded to said intermediate substrate for coupling said intermediate substrate to said frame assembly.

4. A prefabricated wall assembly as set forth in claim 3 wherein said inner foam layer is selected from the group of polyurethane foams, polyurea foams, and combinations thereof.

5. A prefabricated wall assembly as set forth in claim 4 wherein said inner foam layer has a thickness of from about 0.5 to about 5.5 inches.

6. A prefabricated wall assembly as set forth in claim 1 wherein said intermediate substrate has a thickness of from about 0.125 to about 6.00 inches.

7. A prefabricated wall assembly as set forth in claim 1 wherein said outer foam layer has a thickness of from about 0.25 to about 3.50 inches and said outer foam layer has a density of from about 3.00 to about 9.00 pounds per cubic foot.

9. A prefabricated wall assembly as set forth in claim 1 wherein said binder is a polymer selected from the group of acrylic-based polymers or copolymers, styrene-acrylic-based copolymers, styrenebutadiene-based copolymers, vinyl acrylic-based copolymers, vinyl acetate based polymers or copolymers, polyvinylidene chloride, neoprene, natural rubber latex, polyurethane based polymers and combinations thereof.

10. A prefabricated wall assembly as set forth in claim 1 wherein said particles are pre-expanded polymers selected from the group of polystyrene, styrene based-copolymers, polyethylene, polypropylene, polyesters, polyvinylchloride, cellulose acetate, glass beads, fumed silica, graphite, and combinations thereof.

11. A prefabricated wall assembly as set forth in claim 1 wherein said frame assembly has a first end and a second end spaced from said first end defining a length of the prefabricated wall assembly and said outer foam layer is seamless across said length of said frame assembly.

12. A prefabricated wall assembly as set forth in claim 1 wherein said outer foam layer is a preformed panel comprising said plurality of particles and said binder with said preformed panel coupled to said frame assembly.

13. A prefabricated wall assembly as set forth in claim 12 wherein said particles of said outer foam layer of said preformed panel are pre-expanded polymers selected from the group of polystyrene, styrene based-copolymers, polyethylene, polypropylene, polyesters, polyvinylchloride, cellulose acetate, glass beads, fumed silica, graphite, and combinations thereof.

14. A prefabricated wall assembly as set forth in claim 13 wherein said outer foam layer of said preformed panel comprises a binder selected from the group of acrylic-based polymers or copolymers, styrene-acrylic-based copolymers, styrenebutadiene-based copolymers, vinyl acrylic-based copolymers, vinyl acetate based polymers or copolymers, polyvinylidene chloride, neoprene, natural rubber latex, and combinations thereof for binding the particles together to form said preformed panel.

8. (canceled)

15. A method of manufacturing a prefabricated wall assembly for receiving an exterior covering of a building, with said prefabricated wall assembly comprising a frame assembly, an intermediate substrate, and an outer foam layer comprising a plurality of particles and a binder with the particles defining a plurality of pathways extending vertically through the prefabricated wall assembly for allowing airflow and drainage through the prefabricated wall assembly between the frame assembly and he exterior covering, said method comprising the steps of;

providing the frame assembly with a plurality of vertical members coupled between a top member and a bottom member;

coupling the intermediate substrate to an exterior side of the frame assembly,

applying the outer foam layer to the intermediate substrate opposite the frame assembly;

curing the binder of the outer foam layer such that the particles are bonded to the intermediate layer thereby defining the plurality of pathways and forming the prefabricated wall assembly.

16. A method as set forth in claim 15 wherein the prefabricated wall assembly further comprises an inner foam layer and the step of coupling the intermediate substrate is further defined as applying the inner foam layer to the intermediate substrate between the vertical members of the frame assembly to bond the intermediate substrate to the frame assembly.

17. A method as set forth in claim 16 wherein the step of applying the outer foam layer is further defined as spraying a first stream comprising of the binder onto the exterior side of the intermediate substrate to apply the binder to the intermediate substrate.

18. A method as set forth in claim 17 further comprising the step of spraying a second stream comprising of the plurality of particles onto the binder applied to the exterior side of the intermediate substrate.

19. A method as set forth in claim 18 wherein the steps of spraying the first stream and spraying the second stream are performed simultaneously.

20. A method as set forth in claim 15 further comprising the step of mixing the binder and the plurality of particles to form a sprayable composition.

21. A method as set forth in claim 20 wherein the step of applying the outer foam layer is further defined as spraying the sprayable composition onto the exterior side of the intermediate layer to apply the binder and plurality of particles of the sprayable composition on the intermediate substrate.

22. (canceled)

23. A method of manufacturing a prefabricated wall assembly for receiving an exterior covering of a building, with the prefabricated wall assembly comprising a frame assembly, and an outer foam layer, said method comprising the steps of;

providing the frame assembly with a plurality of vertical members coupled between a top member and a bottom member;

providing at least one preformed panel comprising of the outer foam layer having a plurality of particles and a binder that define a plurality of pathways extending vertically through the prefabricated wall assembly to allow airflow and drainage through the preformed panel; and

coupling the preformed panel to the frame assembly to provide the prefabricated wall assembly with the pathways between the frame assembly and the exterior covering.

24. A method as set forth in claim 23 wherein the step of providing the preformed panels is further defined as molding the binder and the plurality of particles of the outer foam layer into the prefabricated panels such that the particles and the binder define the plurality of pathways extending vertically through the prefabricated wall assembly to allow airflow and drainage through the preformed panel.

25. A method as set forth in claim 23 further comprising the step of applying an inner foam layer to the preformed panels between the vertical members of the frame assembly.

26. A method as set forth in claim 25 further comprising the step of applying an inner foam layer is further defined as spraying a foam onto the preformed panels between the vertical members of the frame assembly.

27. A method as set forth in claim 25 further comprising the step of curing the inner foam layer to bond the preformed panel to the frame assembly thereby forming the prefabricated wall assembly.

28. (canceled)