Wall fabrication system and method

a wall and fabrication system technology, applied in the field of building construction, can solve the problems of difficulty in properly filling the cavity, difficulty in ensuring the safety of the user, and widespread application of automatic manufacturing to the manufacture of traditional site-built homes, etc., and achieves the effects of improving insulation, reducing the risk of mold growth, and increasing strength

Inactive Publication Date: 2008-07-17
THE MATTAMY CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0015]Depending on the choice of flowable material, when the flowable material cures it can provide an air barrier from one side of the wall section to the other side of the wall section. Furthermore, the flowable material can be chosen to have a low vapour permeance, and, when coupled with a vapour-barrier primer (applied as a paint to t...

Problems solved by technology

Automation is not yet, however, widely applied to the manufacture of traditional site-built homes.
However, it can be difficult to properly fill the cavity, and the fiberglass bats can be prone to sagging so that the upper portions of the wall are not properly insulated.
Likewise, not all cavities have uniform shapes and so the bats need to be cut to size, leaving the possibility for gaps.
Another disadvantage with fiberglass insulation is that a properly placed vapour barrier is also required.
The vapour barrier can be difficult to install, and in any event presents extra cost and time in the home construction process.
Another problem with vapour barriers is that mould growth...

Method used

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  • Wall fabrication system and method
  • Wall fabrication system and method

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Embodiment Construction

[0040]Referring now to FIG. 1, a wall section for a traditional site-built home is indicated generally at 50. Wall section 50 comprises a plurality of substantially parallel vertical studs 54 transversely affixed to a plurality of substantially parallel horizontal studs 58. Not all vertical studs 54 and horizontal studs 58 are labeled in FIG. 1. Studs 54, 58 define a frame 60 that is covered on one side by drywall 62 or other type of covering such as plywood, wood or the like. Studs 54, 58 act as supports for wall section 50.

[0041]It should be understood that terms such as “horizontal” and “vertical” are used for convenience to assist in understanding the discussion herein, but do not imply herein that studs of a frame need to be arranged in such a manner.

[0042]Studs 54, 58 can be wood and / or metal and / or any other suitable type of home framing material for a traditional site-built home. Studs 54, 58 are affixed to each other using nails, staples and / or any other type of suitable fa...

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PUM

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Abstract

A wall fabrication system and method is provided. In an embodiment, an assembly line comprises one or framing stations and one or more insulation stations. The frame stations are configured to build a wall frame consisting of wall studs and a covering such as drywall. The wall studs and drywall define cavities in the frame which are to be insulated. Optionally, mechanical components such as electrical and plumbing can be installed. The wall section is then transferred to the insulation station. The insulation station is configured to fill the cavities in the wall frame with closed cell foam which is injected in flowable form into each cavity.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]Applicants claim priority of Canadian Application, Ser. No. 2,573,687, filed Jan. 11, 2007.FIELD OF THE INVENTION[0002]The present invention relates generally to building construction and in particular to a wall fabrication system and method.BACKGROUND OF THE INVENTION[0003]Housing is a critical aspect of social living. The construction of houses and other dwellings is therefore a well-known and highly refined art. Construction techniques and esthetic styles are well known for single family dwellings, detached and semi-detached houses, condominiums, apartment buildings, town houses, and the like.[0004]Automation is also broad reaching and used heavily in a broad range of industries and is used to build cars, trucks, planes, electronics, appliances and many other products. Automation techniques are increasingly being applied to the housing industry, and indeed are used heavily in the manufacture of modular and panelized homes. Automation is...

Claims

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Application Information

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IPC IPC(8): E04G21/00
CPCE04C2/386
Inventor GILGAN, PETERMITCHELL, WATERVOHSEMER, PETER
Owner THE MATTAMY CORP
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