Wall Fabrication System and Method

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]This application is a continuation of U.S. application Ser. No. 11 / 676,002, filed Feb. 16, 2007, which claims priority from Canadian Application 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...

AI Technical Summary

Benefits of technology

The system ensures uniform insulation, increased thermal resistance, and enhanced structural strength, reducing the need for traditional fasteners and vapor barriers, while minimizing environmental exposure to hazardous fumes during application.

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 and air leakage can result from punctures that can easily occur in the plastic sheets.

Also, application of a moisture barrier in a damp area could actually trap existing moisture within the wall, particularly where the plastic sheeting becomes wrinkled, with all the attendant problems thereto.

However, this reintroduces a version of the sagging problem with fiberglass insulation, as the liquid insulation tends to flow downwards in the wall cavity, resulting in an uneven distribution of the insulation within the wall cavity.

Overspray is also a serious problem—should the foam be applied to the studs, it can be difficult to attach drywall or other paneling or covering to the wall.

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