Covestro LLC

Michael F Palmosina, Ii

James Leonard Lambach

David M Baily

David D Steppan

Scott Cloherty

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

Methods for manufacturing foam wall structures are described. The methods include placing a wall structure proximate to a robotic arm, orienting an imaging device so that the imaging device on the robotic arm faces a cavity in the wall structure, surveying the cavity using the imaging device, determining a spray foaming pattern to fill the cavity to a selected depth with a foam layer, orienting the spray nozzle so the spray nozzle faces the cavity, and spray-applying the foam-forming composition into the cavity to the selected depth by passing the foam-forming composition through the spray nozzle to form the foam layer. Foam wall structure manufacturing systems that are suitable for carrying out such methods are also described.

Methods and systems for manufacturing foam wall structures

Foam wall structures and methods for making them are described. The wall structures include a frame, a mesh mechanically fastened to a front surface of the frame, a foam panel at least partially abutting and overlying the mesh, and a foam layer disposed in a cavity defined by the frame, the mesh, and the foam panel. Buildings that include such wall structures are also described.

Foam wall structures 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

Foam wall structures and methods for making them are described. The wall structures include a frame, a sheet metal sheathing overlying a front surface of the frame, a foam panel overlying the sheet metal sheathing, and a foam layer disposed in a cavity defined by the frame and the sheet metal sheathing. Buildings that include such wall structures are also described.

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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Baden, PA, United States of America

Michael F Palmosina, Ii