Foam wall structure

A foam wall structure includes a frame, at least one primary support member, and a foam layer. The frame can include: a first member; a second member spaced apart from the first member; and two side members extending between the first and second members. The frame defining a front frame surface and an opposite rear frame surface. The at least one primary support member can be positioned between the two side members and extend between the first and second member. The primary support member defines a front support surface and an opposite rear support surface. The foam layer can be received within at least a portion of the frame and overlies the front surface of the primary support member to form an uninterrupted exposed foam surface. A method of making a foam wall structure is also disclosed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to wall systems, and, in particular, to a foam wall structure.

2. Description of Related Art

Insulated wall panels provide thermal insulation for residential homes and buildings. A wall panel's R-value is its ability to impede heat flow. The greater the ability to impede heat flow, the higher the R-value. Over the years, insulation standards have become more strict, requiring higher R-values and continuous insulation on the exterior side of insulated wall panels. The current market solutions to these stricter requirements are (1) pre-fabricated wall panels that incorporate insulation at the construction site, and (2) Structural Insulated Panels (SIPs).

The pre-fabricated wall panel that incorporates insulation at the construction site is the more widely adopted solution in the market. However, pre-fabricated wall panels that incorporate high-quality insulation at the construction site require a separate sub-contractor for on-site insulation with fiberglass batting, which is known to have suboptimal R-values. Fiberglass is not an air barrier and allows for air intrusion, thus, increasing the probability of condensation and mold growth within wall systems. Furthermore, additional material is necessary to finish the wall (e.g., Oriented Strand Boards (OSBs) and house wrap), and the overall construction process duration is extended, thereby, increasing possible risk of trade scheduling conflicts. Installing insulation onsite also leads to potential inconsistencies in insulation installation, performance, risk, and usage.

The second solution, SIPs, also have several drawbacks. SIPs typically utilize expanded polystyrene (EPS) foam insulation sandwiched between two OSB boards, which only provide thermal performance of about R-4 per inch. Additionally, current SIPs are mainly used by smaller scale home builders with high levels of home customization.

A need, therefore, exists for an insulated wall structure that satisfies the strict industry insulation requirements and that can be made without excessive material and labor costs.

SUMMARY OF THE INVENTION

According to one embodiment of the present invention, a foam wall structure includes a frame, at least one primary support member, and a foam layer. The frame can include: a first member; a second member spaced apart from the first member; and two side members extending between the first and second members. The first member, second member, and two side members each have a front surface and a rear surface that form the front frame surface and the rear frame surface of the frame. The at least one primary support member can be positioned between the two side members and extend between the first and second member. The primary support member defines a front primary support surface and an opposite rear primary support surface corresponding to the front frame surface and rear frame surface. The foam layer can be received within at least a portion of the frame and overlies the front surface of the primary support member to form an uninterrupted exposed foam surface.

According to another embodiment of the present invention, a method of manufacturing a foam wall structure includes: a) providing a frame with at least one primary support member; b) providing a rigid surface having a width equal to or greater than the width of the front frame surface and length equal to or greater than the length of the front frame surface; c) orientating the front frame surface over the rigid surface such that the front frame surface is substantially parallel to the rigid surface; d) depositing foam material into the frame; and e) allowing the foam material to expand within at least a portion of the frame, wherein the foam layer overlies the front support surface of the primary support member to form an uninterrupted exposed foam surface.

The present invention is also directed to a foam wall structure made according to the methods described herein.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of the description hereinafter, spatial orientation terms, if used, shall relate to the referenced embodiment as it is oriented in the accompanying drawing figures or otherwise described in the following description. However, it is to be understood that the embodiments described hereinafter may assume many alternative variations and embodiments. It is also to be understood that the specific devices illustrated in the accompanying figures and described herein are simply exemplary and should not be considered as limiting.

As indicated, in certain embodiments, the present invention is directed to a foam wall structure10that includes a frame11, at least one primary support member17, and a foam layer30with an uninterrupted exposed foam surface31. In certain embodiments, as shown inFIGS. 1-2, the frame11may be defined by a first member12, a second member14spaced apart from the first member12, and two side members16extending between the first member12and the second member14. In certain embodiments, the first member12, second member14, and two side members16each have a front surface12a,14a,16aand a rear surface12b,14b,16bthat define a front frame surface11aand a rear frame surface lib, respectively.

The frame11can be constructed into different shapes depending on its intended use. In certain embodiments, as shown inFIGS. 1-2, the frame11can be constructed as a conventional industry standard rectangular or square frame11. For example, as shown inFIGS. 1-2, the first member12and second member14may be spaced apart and extend parallel to each other, and the two side members16may extend perpendicular to the first member12and second member14so as to form a rectangular or square frame11. The shape and design of the frame11is not so limited and can be constructed into any desired shape. Generally, the shape and design of the frame11is constructed in accordance with the floor plans designed for a particular home or building.

Referring toFIGS. 3-4, in certain embodiments, at least one primary support member17may be positioned between the two side members16. The primary support members17may extend between the first member12and the second member14. The primary support members17may define a front primary support surface17aand a rear primary support surface17b. As shown inFIGS. 3-4, in certain embodiments, the front primary support surface17aand rear primary support surface17bcorrespond to the front frame surface11aand rear frame surface11bof the frame11.

Referring again toFIGS. 3-4, in certain embodiments, the primary support members17may be spaced apart to form cavities18. The cavities18may be defined by the area between the primary support members17, side members16, first member12, and/or second member14. The size of each cavity18will vary based on the size of the frame11, the distance between consecutively positioned primary support members17, and the number of primary support members17present.

Further, the primary support members17, side members16, first member12, and/or second member14may comprise one or more plates, boards, beams, or the like. For example, as shown inFIGS. 1-4, the first member12may include two plates.

In certain embodiments, the two side members16and/or primary support members17are fixedly engaged to the first member12and second member14. For instance, in certain embodiments, the two side members16and/or primary support members17are fixedly engaged to the first member12and second member14with fasteners. Suitable fasteners that can be used with the present invention include, but are not limited to, nails, staples, bolts, screws, and rivets. The first member12, second member14, two side members16, and primary support members17can be made of various materials. For example, the first member12, second member14, two side members16, and primary support members17can be made of wood, metal, fiberglass, plastic, or a combination thereof. The first member12, second member14, two side members16, and primary support members17can be made of the same material or different materials.

Further, the dimensions of the first member12, second member14, two side members16, and primary support members17will vary depending on the intended use of the frame11. The first member12, second member14, two side members16, and primary support members17can each have any dimension. In certain embodiments, the first member12, second member14, two side members16, and primary support members17have the same dimensions. For example, the first member12, second member14, two side members16, and primary support members17may have the same width and height dimensions. In one non-limiting embodiment, the first member12, second member14, two side members16, and primary support members17all have a width and height dimension of nominally 2×4 inches. In another non-limiting embodiment, the first member12, second member14, two side members16, and primary support members17all have a width and height dimension of nominally 2×6 inches.

In certain embodiments, the first member12, second member14, and two side members16have the same dimensions that are different from the dimensions of the primary support members17. For example, the first member12, second member14, and two side members16may have the same width and height dimensions, and the primary support members17may have width and height dimensions that are different from the first member12, second member14, and two side members16. In one non-limiting embodiment, the first member12, second member14, and two side members16have a width and height dimension of nominally 2×6 inches, and the primary support members17have a width and height dimension of nominally 2×4 inches.

In addition to the above, and as shown inFIGS. 5-6, one or more secondary support members20and/or tertiary support members22may be used. The secondary support members20and tertiary support members22may comprise one or more plates, boards, beams, or the like. The secondary support members20and tertiary support members22can be incorporated into the frame11to provide structural support to form spaces for windows and doors, and the like. Further, the secondary support members20and tertiary support members22can have dimensions that are the same or different from the primary support members17, side members16, first member12, and/or second member14. In one embodiment, the secondary support members20and tertiary support members22have greater lengths than the primary support members17, side members16, first member12, and/or second member14.

As shown inFIGS. 5-6, the secondary support members20may have a front secondary support surface20aand a rear secondary support surface (not shown) that correspond with the front and rear frame surfaces11a,11band the front and rear primary support surface17a,17b. Similarly, the tertiary support members22may have a front tertiary support surfaces22aand a rear tertiary support surface22b(shown inFIG. 17) that correspond with the front and rear frame surfaces11a,11band the front and rear primary support surfaces17a,17b.

In certain embodiments, the secondary support members20extend between and attach to primary support members17, or alternatively, the secondary support members20extend between and attach to a primary support member17and a side member16. In some embodiments, tertiary support members22extend between two secondary support members20or between a secondary support member22and the first member12and/or second member14.

In certain embodiments, the secondary support members20, tertiary support members22, primary support members17, side members16, first member12, and/or second member14form a secondary cavity26. As shown inFIGS. 5-6, the secondary cavity26can be used as a space for a window, door, or any other opening. For example, in certain embodiments, the secondary support members20, tertiary support members22, primary support members17, side members16, first member12, and second member14can be constructed as a conventional industry standard rectangular or square wall panel having a window, door, or any other opening. For example, referring toFIG. 5, a rectangular or square wall panel having a window can be formed as follows: a first member12and second member14may be spaced apart and extend parallel to each other; two side members16may extend between the first member12and second member14in a direction perpendicular to the first member12and second member14; primary support members17may be positioned between the side members16and extend between the first member12and second member14in a direction perpendicular to the first member12and second member14; two secondary support members20may be spaced apart and extend between primary support members17in a direction parallel to the first member12and second member14; and two tertiary support members22may be spaced apart and extend between the two secondary members20in a direction perpendicular to the secondary support members20and the first member12and second member14. In addition, primary support members17can also extend between the secondary members20and the first member12and/or second member14. As shown inFIG. 5, a secondary cavity26is formed between the secondary support members20and tertiary support members22. The resulting rectangular or square wall panel can be used in a residential home or building. The shape and design is not so limited and can assume any shape and design as desired.

In certain embodiments, additional support members and structural elements may also be used depending on the intended use of the foam wall structure10. For example, and as shown inFIGS. 5 and 6, a header28may be used to provide additional support for a door or window. Other additional support members may be used for structural purposes, design purposes, and the like.

In certain embodiments, a foam material can be deposited into the frame11. As used herein, the term “foam material” refers to a substance that is formed by trapping pockets of gas in a liquid or solid. In certain embodiments, the foam material is a closed-cell foam. As used herein, “closed-cell foam” refers to foam that contains discrete, non-interconnecting cells. Non-limiting examples of foam material that can be used with the present invention include materials made with polyurethane, polyisocyanurate (also referred to as polyiso), and mixtures thereof.

In some embodiments, the foam material may be substantially free, may be essentially free, and may be completely free of halogen containing flame retardant additives. The term “halogen” refers to the halogen elements, which include fluorine, chlorine, bromine and iodine, and the term “halogen containing flame retardant additives” refers to a substance that may be used to inhibit or resist the spread of fire and which contains halogen groups such as a fluoro, chloro, bromo and/or iodo group. Further, the term “substantially free” as used in this context means the foam material contains less than 1000 parts per million (ppm), “essentially free” means less than 100 ppm, and “completely free” means less than 20 parts per billion (ppb) of halogen containing flame retardant additives.

As shown inFIGS. 3-4and7-8, the foam material can be deposited into the frame11such that the foam material forms a foam layer30within at least a portion of the frame11between the front frame surface11aand the rear frame surface lib. As shown inFIG. 7-8, the foam layer30may extend beyond the front primary support surfaces17asuch that the foam layer30overlies the front support surfaces17ato form a continuous or uninterrupted exposed foam surface31. As used herein, “continuous or uninterrupted foam layer” refers to a foamed material that is connected or bonded along at least one path without a break or interruption.

In certain embodiments, referring to FIGS.3and7-8, the foam layer30extends beyond the front primary support surfaces17aand the front frame surface11a. As such, the foam layer30forms a continuous or uninterrupted exposed foam surface31over the front primary support surfaces17aand the front frame surface11a, which can be seen in the top cross-sectional view ofFIG. 7and the side cross-sectional view ofFIGS. 8A and 8B. As shown inFIGS. 7-8, the continuous or uninterrupted exposed foam surface31can extend over the entire front frame surface11a.

Referring to FIGS.9and11-12, in certain embodiments, the foam layer30does not extend beyond the front frame surface11a, and only extends beyond the front primary support surfaces17a. Accordingly, in some embodiments, the foam layer30forms a continuous or uninterrupted exposed foam surface31over the front primary support surfaces17aand is flush or contained between the front and rear frame surfaces11a,11b. As shown inFIGS. 11-12, the continuous or uninterrupted exposed foam surface31can overlay all the front primary support surfaces17a.

Referring toFIGS. 7 and 11, the foam layer30can be dimensioned to expand from the uninterrupted exposed surface31to a position intermediate the front frame surface11aand rear frame surface11b, thereby forming a gap or opening40within the foam wall structure10between the foam layer30and the rear frame surface11b.FIGS. 4 and 10further show that this gap40can be used as an area to incorporate home utility components42such as electrical wires, cords, heating and cooling pipes, and plumbing fixtures. These home utility components42may be inserted into the gap40located between the foam layer30and the rear frame surface11bsuch that utility components42are not surrounded or contacting the foam layer30. In certain embodiments, the gap40comprises at least two inches as measured between the foam layer30and the rear frame surface11b.

In certain embodiments, when secondary support members20and/or tertiary support members22are used with the foam wall structure10to form a secondary cavity26, the secondary cavity26can be free of foam. For example, in some embodiments, the foam layer30does not extend beyond and over the front secondary support surfaces20aof the secondary members20, the front tertiary support surfaces22aof the tertiary support members22, and/or beyond and over at least a portion of the front surfaces of other members that help form the secondary cavity26.FIG. 13shows a top cross-sectional view with the foam layer30not extending beyond the front tertiary support surfaces22aaccording to one embodiment.

Further, the foam layer30can be formed in-situ during the manufacturing process. The term “formed in-situ during the manufacturing process” refers to the formation of a foam layer30with an uninterrupted exposed foam surface31as described herein during manufacturing of the foam wall structure10off-site at a facility remote or away from a building construction site. As such, the foam layer30with an uninterrupted exposed foam surface31may not be formed at a construction site as is required by conventional methods.

The foam layer30having a continuous or uninterrupted exposed foam surface31is able to fill tight spaces and seal gaps that are not visible to the naked eye. The foam layer30with an uninterrupted exposed foam surface31also acts as a vapor and thermal insulating barrier, which reduces energy consumption in buildings and residential homes when the present invention is used as a wall panel. In addition, the foam layer30with an uninterrupted exposed foam surface31provides structural stability to the foam wall structure10such as improved wall racking strength. As used herein, “wall racking strength” refers to the ability of a wall structure to maintain its shape under duress.

Referring toFIGS. 7 and 11, in certain embodiments, the continuous or uninterrupted exposed foam surface31may include a coating36adhered to at least a portion of the exposed foam surface31. As used herein, the term “coating” includes a partial or continuous film or layer that can be applied to a surface. Non-limiting examples of coatings36that can be adhered or attached to the exposed foam surface31includes coatings36that provide protection from ultraviolet (UV) radiation, weathering, or a combination thereof. The coating36can also provide stability to the exposed foam surface31. For example, the coating36may include fibrous materials such as, but not limited to, glass fibers.

Further, in certain embodiments, the foam wall structure10does not include a rigid sheathing layer. As used herein, the term “rigid sheathing layer” refers to a layer applied to at least a portion of the front frame surface11aor rear frame surface11b. Non-limiting of sheathing layers include boards, plates, and the like. For instance, the foam wall structure does not include foam boards, wood boards, metal boards, gypsum boards, paper boards, polymeric foam boards, plates, and the like. Examples of such sheathing layers are disclosed in U.S. Pat. No. 8,397,465 and U.S. Patent Application Publication No. 2012/0011792. The foam wall structure10, excluding such materials according to the present invention, is able to flex or deform under a load and return to its original design while retaining its structural stability, racking strength, and other physical characteristics.

The present invention is also directed to methods of making a foam wall structure10. In certain embodiments, a method of making a foam wall structure10includes first constructing a frame11having at least one primary support member17. The frame11having at least one primary support member17can be constructed in accordance with any of the embodiments disclosed herein. Referring toFIGS. 14-17, after constructing the frame11with at least one primary support member17, the front frame surface17acan be orientated over a rigid surface50such that the front frame surface11ais positioned parallel or at least substantially parallel to the rigid surface50. A “rigid surface” refers to any surface that is capable of receiving the frame11without bending, flexing, or moving. In certain embodiments, and as shown inFIGS. 14-17, the rigid surface50has a width equal to or greater than the width of the front frame surface11aand a length equal to or greater than the length of the front frame surface11a. In one non-limiting example, the rigid surface50is substantially horizontal.

After orientating the front frame surface17aover the rigid surface50, a foam material can be deposited into the frame11. The foam material may be deposited with an automated delivery device. Alternatively, the foam may be deposited using various other devices including, but not limited to, a foam dispensing gun that is controlled and carried by an individual user. In one embodiment, as shown inFIGS. 14-17, the foam material is deposited with an automated foam dispensing rig60that can be calibrated to dispense a pre-determined amount of foam. The foam dispensing rig60can include one or more nozzles62. The nozzles62can be positioned over the frame11of the foam wall structure10so that each nozzle62sprays or pours foam into cavities18located within the frame11such as the cavities18shown inFIG. 3. A foam dispensing rig60with a plurality of nozzles62makes it possible to dispense foam quickly and efficiently. In certain embodiments, the nozzles62can move into different positions.

Referring toFIGS. 14-17, in certain embodiments, the foam material may be deposited so that the foam material contacts the rigid surface50. As shown inFIG. 14, the material may be deposited so that a foam layer30extends beyond the front primary support surfaces17aand the front frame surface11a. As such, the foam layer30forms a continuous or uninterrupted exposed foam surface31over the front primary support surfaces17aand the front frame surface11a.

Referring toFIG. 16, in certain embodiments, the foam material is deposited so that the foam layer30does not extend beyond the front frame surface11a. Accordingly, in some embodiments, the foam material is deposited so that a foam layer30forms a continuous or uninterrupted exposed foam surface31over the front primary support surfaces17aand is flush or contained between the front frame surface11aand rear frame surface11b.

As shown inFIGS. 15-16, the foam material can be deposited so that the foam layer30can expand from the uninterrupted exposed surface31to a position intermediate the front frame surface11aand rear frame surface11b. A gap or opening40can therefore be formed between the foam layer30and the rear frame surface11bto incorporate home utility components42such as electrical wires, cords, heating and cooling pipes, and plumbing fixtures, as can be seen inFIGS. 4 and 10.

Referring toFIG. 14, the front frame surface11acan be moved away from or elevated to a position above the rigid surface50. The front frame surface11acan be elevated above the rigid surface50using an elevation device including, but not limited to, an industrial panel raiser. In operation, the elevation device holds the front frame surface11asecurely in place at a specified distance above the rigid surface50. The higher it is elevated above the surface, the farther the foam layer30will extend beyond and over the front primary support surfaces17aand/or the front frame surface11a. Alternatively, in some embodiments, the front frame surface11acan be placed onto the rigid surface50, as shown inFIG. 15.

As shown inFIGS. 14 and 16, a form70can be used to prevent foam material from extending out from the outside perimeter of the frame11. As used herein, a “form” refers to a barrier that prevents foam or other materials from expanding outside the perimeter of the frame11. The form70may be positioned around the outside perimeter of the frame11. As shown inFIG. 16, a second form72may be positioned between adjacent primary support members17to prevent foam material30from expanding into undesired areas.

Referring toFIG. 14, in one non-limiting embodiment, the front frame surface11acan be elevated above a rigid surface50and foam material can be deposited such that a foam layer30is formed with an uninterrupted exposed surface31over the front primary support surfaces17aand the front frame surface11a. The foam material can be deposited so that the foam layer30can expand from the uninterrupted exposed surface31to a position intermediate the front frame surface11aand rear frame surface lib. A form70can be placed around the perimeter of the frame11to prevent foam material from expanding outside the perimeter of the frame11.

As shown inFIG. 15, in another non-limiting embodiment, the front frame surface11acan be placed onto the rigid surface50. As shown inFIG. 15, foam material can be deposited such that a foam layer30is formed with an uninterrupted exposed surface31extending over the front primary support surfaces17aand not the front frame surface11a. As such, the foam layer30forms a continuous or uninterrupted exposed foam surface31over the front primary support surfaces17aand is flush or contained between the front and rear frame surface11a,11b.

As indicated, the foam wall structure10can also include secondary support members20and tertiary support members22that form a secondary cavity26within the frame11. Accordingly, in certain embodiments, the methods described herein include constructing a frame11having one or more secondary support members20and tertiary support members22. In certain embodiments, to prevent foam material from entering the secondary cavity26, the dimensions of the secondary support members20and/or tertiary support members22are greater than the dimensions of the primary support members17.FIG. 17shows a top cross-sectional view of the process of depositing foam into a frame11with tertiary support members22having a greater height than the primary support members17.

Referring toFIG. 14-17, in certain embodiments, a coating36is deposited onto at least a portion of the rigid surface50. The coating36can be deposited to provide protection from ultraviolet (UV) radiation, weathering, friction, contamination, or a combination thereof. The coating36can also provide stability to the uninterrupted exposed foam surface31. For example, the coating may include fibrous materials such as, but not limited to, glass fibers. The coating36can also be applied as a release coat that can include, for example, a wax material. The release coat allows the uninterrupted exposed foam surface31to separate from the rigid surface50.

In certain embodiments, the coating36deposited onto at least a portion of the rigid surface50forms a film. To keep the film aligned along the rigid surface50, the rigid surface50can include perforations, holes and the like where pressure can be lowered so as to pull the film against the rigid surface50. In one embodiment, the rigid surface50is connected to a vacuum source V such as a vacuum table as shown inFIG. 15.

After the foam layer30has expanded, the formed foam wall structure10can be removed from the rigid surface50and shipped directly to a job site for use as a wall panel. The foam wall structure10can be installed without any additional steps, thereby reducing the number of sub-contractors necessary to complete the installation of a wall at a construction site. In addition, the foam wall structure10does not require additional materials such as rigid sheathing, OSB boards, and house wrap that are typically used in current residential building practices. Therefore, insulation costs would decrease. The present invention would also decrease the overall cost per square foot per R-value.

The foam wall structure10also imparts a higher wall racking strength and improves thermal performance in comparison to existing wall solutions through the introduction of a foam layer30with the uninterrupted foam surface31. Further, the foam wall structure10will help meet future R-value industry standards that are expected to increase in certain regions, while still utilizing current wall designs. With current fiberglass insulation, builders would have to convert 2×4-based wall designs to 2×6-based wall designs to ensure enough wall cavity capacity for additional insulation to meet such higher standards.

The methods described herein also improve the consistency of installing insulation, and make it easy to install electrical and plumbing components in the gap or opening40of a wall panel. The present invention would also decrease the overall cost per square foot per R-value.

The foam wall structure10is not limited for use in newly constructed homes and can be used for residential exterior insulation retrofit applications. Accordingly, another aspect of the present invention is the replacement of wall panels in older homes and buildings with the foam wall structure10described herein.

While several embodiments of the invention were described in the foregoing detailed description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive.