Prefabricated Wall Assembly Having An Insulating Foam Layer

Abstract

A prefabricated wall assembly receives an exterior covering of a building. The prefabricated wall assembly includes a frame assembly and an insulating foam layer. The frame assembly includes a top member, a bottom member opposite the top member, and a plurality of vertical members coupled to and extending between the top and bottom members. The frame assembly also has an interior side and an exterior side opposite the interior side. The insulating foam layer is disposed between the plurality of vertical members of the frame assembly and also extends from the exterior side of the frame assembly terminating in a plurality of integral ribs. An exterior surface of the insulating foam layer is presented between the plurality of ribs. The ribs space the exterior covering from the exterior surface of the insulating foam layer for allowing airflow and drainage between the prefabricated wall assembly and the exterior covering.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application claims priority to and all the advantages of U.S. Provisional Patent Application No. 61 / 498,094 filed on Jun. 17, 2011, which is incorporated by reference.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The invention generally relates to a prefabricated wall assembly. More specifically, the invention relates to a prefabricated wall assembly having an insulating foam layer.[0004]2. Description of the Related Art[0005]Prefabricated wall assemblies for use as walls of a building, such as residential buildings, or commercial buildings, are known in the art. A conventional prefabricated wall assembly is assembled offsite at a factory or warehouse. After assembly, the conventional prefabricated wall assembly is transported on-site were the building is to be constructed. The conventional prefabricated wall assembly reduces construction time to construct the building and reduces the labor cost for constructing the ...

AI Technical Summary

Benefits of technology

The invention is a prefabricated wall assembly with an insulating foam layer that creates airflow and drainage between the wall and the exterior covering, preventing environmental elements like water from entering the building. The foam layer is also designed to protect the frame assembly and improve energy efficiency.

Problems solved by technology

However, because the insulating layer comprises panels, which are preformed, a plurality of seams result between adjacent panels.

The seams can be a source of reduced R-value and provide a path for weather elements, such as wind and water, to enter the frame assembly, which is undesirable.

Typically, once the weather elements penetrate the conventional prefabricated wall assembly, the weather elements penetrate the frame assembly and eventually the building itself, which causes damage to an interior sheathing, such as drywall or gypsum board.

However, over time, the weather elements can penetrate or circumvent the barrier layer, thus penetrating the conventional prefabricated wall assembly.

Images