Patent ID: 8696966
Filing Date: 2014-04-15
Classification: B29C,E04B

Abstract:
1. A method of fabricating a wall structure comprising: positioning a wall frame substantially adjacent and parallel to a first surface of a support platform wherein said wall frame comprises a first support member that is substantially parallel to a second support member, each of said first and second support members comprising a first end and a second end, and wherein a third support member connects a first portion of the first support member to a first portion of the second support member and a fourth support member connects a second portion of the first support member to a second portion of the second support member, said wall frame being offset from the first surface of the support platform such that a space is formed between the wall frame and the first surface of the support platform, wherein the wall frame comprises an interior space defined by the support members, and wherein a release layer is disposed on the first surface of the support platform and is positioned between the first surface of the support platform and the wall frame; contacting a first overflow lip against at least a portion of a first side of the support platform and at least a first portion of the wall frame, a second overflow lip against at least a portion of a second side of the support platform and at least a second portion of the wall frame, a third overflow lip against at least a portion of a third side of the support platform and at least a third portion of the wall frame, and a fourth overflow lip against at least a portion of a fourth side of the support platform and at least a fourth portion of the wall frame, wherein each of the first, second, third, and fourth overflow lips have a release layer disposed on a first surface of each overflow lip, said first surface of each of said overflow lips and the first surface of the support platform defining a cavity; applying a polyurethane foam composition onto the release layer disposed on the first surface of the support platform by introducing the polyurethane foam composition through the interior space and into the cavity that is defined by the first surface of the support platform and the first surface of each first, second, third, and fourth overflow lips until such foam is in contact with at least a portion of the wall frame and fills at least a portion of the interior space and at least a portion of the space that is formed between the wall frame and the first surface of the support platform; curing the polyurethane foam composition to form a polyurethane foam layer thereby attaching the polyurethane foam layer to the wall frame; and releasing the cured polyurethane foam layer and the attached wall frame from each release layer thereby forming the wall structure by removing the support platform and each of the first, second, third, and fourth overflow lips from the cured polyurethane foam layer and removing any release layer attached to the cured polyurethane foam layer.