Prefabricated Wall Assembly Having An Outer 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 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.
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Accused Products
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.
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Citations
28 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 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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13, 14)
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8. (canceled)
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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;
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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. - View Dependent Claims (16, 17, 18, 19, 20, 21)
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22. (canceled)
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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;
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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. - View Dependent Claims (24, 25, 26, 27)
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28. (canceled)
Specification