Prefabricated wall assembly having an outer foam layer

• US 9,702,152 B2
• Filed: 06/15/2012
• Issued: 07/11/2017
• Est. Priority Date: 06/17/2011
• Status: Active Grant

• Current Assignee: BASF SE
• Original Assignee: BASF SE
• Inventors: Sievers, Michael J., McNulty, Michael J., Drewery, Michael, Fox, Paul J., Davenport, Rick, Poma, Mary, Swanson, Colby A.
• Primary Examiner(s): Katcheves, Basil
• Assistant Examiner(s): IHEZIE, JOSHUA K
• Application Number:
  US14/126,664
• Publication Number:
  US 20140115989A1
• Time in Patent Office: 1,852 Days
• Field of Search: 5230912, 523097, 524811, 52602
• 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 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, wherein said top member, said bottom member, and said vertical members are made of wood;

an inner foam layer disposed between and bonded to said vertical members of said frame assembly, wherein said inner foam layer is a sprayed foam selected from the group of polyurethane foams, polyurea foams, and combinations thereof;

an outer foam layer directly adjacent said exterior side of said frame assembly and extending from said exterior side of said frame assembly and terminating at an exterior surface of said outer foam layer;

wherein said outer foam layer is a non-concrete layer comprising a plurality of pre-expanded polymeric beads having multiple bead sizes and a binder that define a plurality of non-straight pathways extending vertically from said top member toward said bottom member of said frame assembly through said outer foam layer for allowing airflow and drainage, wherein said pre-expanded polymeric beads are selected from the group of polystyrene, styrene based-copolymers, polyethylene, polypropylene, polyesters, polyvinylchloride, cellulose acetate; and

an exterior covering disposed directly adjacent said exterior surface of said outer foam layer and a plurality of fasteners extending through said exterior covering and said outer foam layer and attached to said frame assembly.

2. A 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 wall assembly as set forth in claim 2 wherein said intermediate substrate has a thickness of from 0.125 to 6.00 inches.

4. A wall assembly as set forth in claim 1 wherein said inner foam layer has a thickness of from 0.5 to 5.5 inches.

5. A wall assembly as set forth in claim 1 wherein said outer foam layer has a thickness of from 0.25 to 3.50 inches and said outer foam layer has a density of from about 1.00 to 5.00 pounds per cubic foot.

6. A 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.

7. A 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 wall assembly and said outer foam layer is seamless across said length of said frame assembly.

8. A wall assembly as set forth in claim 1 wherein said outer foam layer is a preformed panel.

9. A wall assembly as set forth in claim 1 wherein said exterior surface of said outer foam layer is free of vertical grooves in communication with said pathways.

10. A 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, wherein said top member, said bottom member, and said vertical members are made of wood;

an inner foam layer disposed between and bonded to said vertical members of said frame assembly, wherein said inner foam layer is a sprayed foam selected from the group of polyurethane foams, polyurea foams, and combinations thereof, wherein said inner foam layer has a thickness of from 0.5 to 5.5 inches;

an outer foam layer directly adjacent said exterior side of said frame assembly and extending from said exterior side of said frame assembly and terminating at an exterior surface of said outer foam layer;

wherein said outer foam layer is a non-concrete layer comprising a plurality of pre-expanded polymeric beads having multiple bead sizes and a binder that define a plurality of non-straight pathways extending vertically from said top member toward said bottom member of said frame assembly through said outer foam layer for allowing airflow and drainage, wherein said pre-expanded polymeric beads are selected from the group of polystyrene, styrene based-copolymers, polyethylene, polypropylene, polyesters, polyvinylchloride, cellulose acetate, 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, wherein said outer foam layer has a thickness of from 0.25 to 3.50 inches and said outer foam layer has a density of from 1.00 to 5.00 pounds per cubic foot, wherein said exterior surface of said outer foam layer is free of vertical grooves in communication with said pathways;

wherein said frame assembly has a first end and a second end spaced from said first end defining a length of the wall assembly and said outer foam layer is seamless across said length of said frame assembly; and

an exterior covering disposed directly adjacent said exterior surface of said outer foam layer and a plurality of fasteners extending through said exterior covering and said outer foam layer and attached to said frame assembly.

11. A 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, wherein said top member, said bottom member, and said vertical members are made of wood;

an inner foam layer disposed between and bonded to said vertical members of said frame assembly, wherein said inner foam layer is a sprayed foam selected from the group of polyurethane foams, polyurea foams, and combinations thereof, wherein said inner foam layer has a thickness of from 0.5 to 5.5 inches;

an outer foam layer directly adjacent said exterior side of said frame assembly and extending from said exterior side of said frame assembly and terminating at an exterior surface of said outer foam layer;

wherein said outer foam layer is a non-concrete layer comprising a plurality of pre-expanded polymeric beads having multiple bead sizes and a binder that define a plurality of non-straight pathways extending vertically from said top member toward said bottom member of said frame assembly through said outer foam layer for allowing airflow and drainage, wherein said pre-expanded polymeric beads are selected from the group of polystyrene, styrene based-copolymers, polyethylene, polypropylene, polyesters, polyvinylchloride, cellulose acetate, 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, wherein said outer foam layer has a thickness of from 0.25 to 3.50 inches and said outer foam layer has a density of from 1.00 to 5.00 pounds per cubic foot, wherein said exterior surface of said outer foam layer is free of vertical grooves in communication with said pathways;

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 bonded to said inner foam layer for coupling to said frame assembly, wherein said intermediate substrate has a thickness of from 0.125 to 6.00 inches;

wherein said frame assembly has a first end and a second end spaced from said first end defining a length of the wall assembly and said outer foam layer is seamless across said length of said frame assembly; and

an exterior covering disposed directly adjacent said exterior surface of said outer foam layer and a plurality of fasteners extending through said exterior covering and said outer foam layer and attached to said frame assembly.