Pre-fabricated Insulated Wall Structure Spray Foam Application
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Solution Overview
Problem
Current methods for making pre-fabricated insulated wall structures face challenges such as suboptimal R-values, air barriers, and increased material and labor costs, as well as inconsistencies in insulation installation and performance.
Innovation Solution
A method involving a track conveyor system to efficiently manufacture pre-fabricated insulated wall structures by attaching a foam panel to a frame, conveying it upright to a spray foam application station, and applying spray foam into the frame cavity to form a cohesive foam layer adhering to the foam panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fiberglass batting is used for insulation at the construction site, then the installation process is simplified, but the R-value and thermal performance become suboptimal
Solution Approach 1:
The patent changes the insulation material from fiberglass batting to spray foam insulation, fundamentally altering the material parameters to achieve both high R-value (superior thermal performance) and consistent installation. The spray foam expands to fill cavities completely, providing reliable insulation performance without the variability associated with manual fiberglass installation.
Solution Approach 2:
The patent replaces the mechanical installation process of fiberglass batting with a chemical application process using spray foam. The spray foam is applied through a spraying mechanism that automatically fills and expands within the cavity, eliminating the need for manual placement and compression of fiberglass materials.
2Adaptability or versatility
If fiberglass insulation is installed onsite, then material selection is flexible, but air barriers are compromised leading to condensation and mold growth
Solution Approach 1:
The patent changes the material properties by using spray foam insulation that cures to form a continuous, seamless barrier. This material parameter change provides both thermal insulation and an effective air barrier, preventing air intrusion, condensation, and mold growth while maintaining flexibility in application.
Solution Approach 2:
The spray foam insulation acts as a composite solution that combines thermal insulation properties with air barrier functionality in a single material system. This eliminates the need for separate air barrier materials and provides integrated protection against air intrusion and moisture-related issues.
3Manufacturing precision
If additional materials are used to finish the wall, then the wall structure is more complete, but material and labor costs increase
Solution Approach 1:
The patent merges multiple functions into the spray foam insulation material itself. The spray foam provides thermal insulation, air barrier, vapor barrier, and cavity filling in a single application, eliminating the need for separate materials and layers that would otherwise be required to achieve complete wall structure functionality.
Solution Approach 2:
The spray foam insulation is applied locally to fill specific wall cavities with precise coverage. The material expands to conform exactly to the cavity shape, providing complete filling and sealing at the appropriate locations without requiring additional finishing materials to achieve structural completeness.
4Adaptability or versatility
If insulation is installed onsite, then the construction process is flexible, but the overall construction duration is extended
Solution Approach 1:
The patent replaces the time-consuming mechanical installation process of fiberglass batting with a rapid spray foam application process. The spray foam is applied quickly, expands immediately to fill cavities, and cures in place, dramatically reducing the time required for insulation installation while maintaining construction flexibility.
Solution Approach 2:
The spray foam application provides continuous insulation coverage as it is sprayed into and expands within the wall cavities. This continuous application process eliminates the segmentation and jointing required in traditional fiberglass installation, reducing overall construction time while maintaining process flexibility.
5Ease of operation
If fiberglass insulation is installed manually, then installation is straightforward, but inconsistencies in installation quality occur
Solution Approach 1:
The patent replaces manual fiberglass installation with an automated spray foam application system. The spraying mechanism delivers consistent material application, and the foam's expansion properties ensure uniform filling of cavities, eliminating the variability and inconsistencies associated with manual installation techniques.
Solution Approach 2:
The spray foam insulation is self-leveling and self-filling as it expands within the cavity. The material automatically conforms to the cavity shape and fills gaps uniformly without requiring manual adjustment or manipulation, ensuring consistent installation quality while simplifying the installation process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of pre-fabricated insulated wall structures with improved thermal performance, reduced material and labor costs, and enhanced consistency in insulation installation, while also simplifying the installation process and reducing the need for additional materials.
Implementation Method 1
a foam layer received within at least a portion of one of the voids within the frame, wherein the foam layer adheres to at least a portion of the polyiso panel
Data Source
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AI summary
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.