Covestro LLC

David M Baily

James Leonard Lambach

Michael F Palmosina, Ii

David D Steppan

Eric C Giles

Michael F Palmosina Ii

Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

Modified foam wall structures with high racking strength and methods for their manufacture

Wall structures and methods of manufacturing wall structures are described. The wall structures include a frame, a foam panel attached to the frame, a brace disposed in a cavity defined by the frame, and a foam layer. The wall structures can impart a high wall racking strength and good thermal performance through the combination of the foam layer, brace, and the foam panels.

Foam wall structures with high shear strength and methods for the manufacture thereof

Prefabricated insulated floor assemblies, methods for manufacturing such assemblies, and use of these floor assemblies in a building are described. The assemblies include a sheathing panel, I-joists, and rigid foam insulation boards positioned in a cavity formed by the sheathing panel and the I-joists.

Floor assemblies, methods for their manufacture, and the use of such assemblies in a building

Insulated buildings are described. The building include: (a) a sloped roof that is a prefabricated insulated roof assembly; (b) a generally horizontally arranged flooring assembly having an end that is arranged over a wall structure and under the sloped roof assembly; (c) a sloped member that is arranged over the end of the flooring assembly that is over the wall structure, and (d) a rigid foam insulation member arranged in the cavity of the roof assembly so as to bridge a lower surface of a rigid foam insulation board in the roof assembly to the sloped member.

Buildings with continuous insulation bridging a roof assembly and a floor assembly

Prefabricated insulated roof assemblies, methods for manufacturing such assemblies, and use of these roof assemblies in a building are described. The assemblies include a sheathing panel comprising an inset solar panel, I-joists, and a rigid foam insulation board positioned in a cavity formed by the sheathing panel and the I-joists.

Roof assemblies with inset solar panels, methods for their manufacture, and the use of such assemblies in a building

Prefabricated insulated roof assemblies, methods for manufacturing such assemblies, and use of these roof assemblies in a building are described. The assemblies include a sheathing panel, I-joists, and rigid foam insulation boards positioned in a cavity formed by the sheathing panel and the I-joists.

Roof assemblies, methods for their manufacture, and the use of such assemblies in a building

Methods of manufacturing wall structures having high racking strength are described in this specification. The methods include spray applying a foam-forming composition into a cavity of a wall structure, wherein the wall structure is disposed in a climate-controlled spray application station and allowing the foam-forming material to expand within at least a portion of the cavity to form a foam layer deposited in the cavity. In the methods, the foam layer is formed in-situ during the manufacturing method, and the density of the foam layer is selected and the relative humidity and dew point of the air in the climate-controlled spray application station throughout the spray applying is selected so that the wall structure has a racking strength of at least 500 pounds per linear foot.

Methods for manufacturing pre-fabricated insulated foam wall structures with high racking strength and related pre-fabricated wall structures

Methods of manufacturing pre-fabricated insulated wall structures are described in this specification. The methods include (a) attaching a foam panel to a front frame surface of a substantially horizontally positioned frame; (b) placing the frame having the foam panel attached thereto on a track conveyor configured to convey the frame having the foam panel attached thereto in a substantially upright position; (c) conveying the frame having the foam panel attached thereto on the track conveyer in a substantially upright position to a spray foam application station; and (d) spray applying a spray foam composition into a cavity of the frame to form a substantially upright positioned wall structure having a foam layer deposited in the cavity in which the foam layer adheres to the foam panel. Also disclosed are track conveyors suitable for use in such methods.

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Upper Saint Clair, PA, United States of America

David M Baily