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.

1 . A prefabricated wall assembly for receiving an exterior covering of a building, said prefabricated wall assembly comprising:
 a frame assembly having a top member, a bottom member opposite said top member, and a plurality of vertical members coupled to and extending between said top and bottom members with said frame assembly having an interior side and an exterior side opposite said interior side; and   an insulating foam layer disposed between said plurality of vertical members of said frame assembly and extending from said exterior side of said frame assembly;   wherein said insulating foam layer terminates in a plurality of integral ribs opposite said frame assembly with an exterior surface of said insulating foam layer presented between said plurality of ribs and with said plurality of ribs spacing the exterior covering from said exterior surface of said insulating foam layer to allow airflow and drainage between said prefabricated wall assembly and the exterior covering.   
     
     
         2 . A prefabricated wall assembly as set forth in  claim 1  wherein said frame assembly has a first end and a second end spaced from said first end defining a length of the prefabricated wall assembly and said insulating foam layer is seamless across said length of said frame assembly. 
     
     
         3 . A prefabricated wall assembly as set forth in  claim 1  wherein said insulating foam layer comprises a foam selected from the group of polyurethane foams, polyurea foams, and combinations thereof. 
     
     
         4 . A prefabricated wall assembly as set forth in  claim 1  wherein said insulating foam layer comprises a sprayable foam selected from the group of polyurethane foams, polyurea foams, and combinations thereof. 
     
     
         5 . A prefabricated wall assembly as set forth in  claim 1  wherein each of said plurality of ribs has a centerline that is aligned with a centerline of one of said plurality of vertical members. 
     
     
         6 . A prefabricated wall assembly as set forth in  claim 1  wherein said insulating foam layer between said frame assembly and said exterior surface of said insulating foam layer has a first thickness of from about 0.75 to about 1.5 inches. 
     
     
         7 . A prefabricated wall assembly as set forth in  claim 1  wherein each of said plurality of ribs extends from said exterior surface of said insulating foam layer a distance of from about 0.5 to about 1.0 inches. 
     
     
         8 . A prefabricated wall assembly as set forth in  claim 1  wherein said insulating foam layer terminates at an interior surface spaced from said exterior surface with said insulating foam layer having a second thickness measured from said exterior side of the frame assembly to said interior surface of said insulating foam layer of from about 0.5 inches to about a nominal width of said frame assembly. 
     
     
         9 . A prefabricated wall assembly as set forth in  claim 1  wherein a distance between said plurality of vertical members is of from about 1 to about 30 inches. 
     
     
         10 . A prefabricated wall assembly as set forth in claim in  claim 1  further comprising a vapor retarder coupled to said exterior surface of said insulating material. 
     
     
         11 . A prefabricated wall assembly as set forth in  claim 10  wherein said vapor retarder is a sprayable vapor retarder. 
     
     
         12 . A prefabricated wall assembly as set forth in  claim 1  wherein said frame assembly is coupled together by said insulating layer such that said frame assembly is free of fasteners. 
     
     
         13 . A prefabricated wall assembly as set forth in  claim 1  wherein each of said plurality of ribs has a radius of from about 0.125 to about 2.00 inches. 
     
     
         14 . A method of manufacturing a prefabricated wall assembly comprising a frame assembly and an insulating layer extending from the frame assembly with a plurality of ribs integral with the insulating layer and extending from the insulating layer for spacing an exterior covering from the insulating material to allow airflow and drainage between the prefabricated wall assembly and the exterior covering
 providing the frame assembly with a plurality of vertical members coupled between a top member and a bottom member;   positioning the frame assembly adjacent a mold such that a cavity is defined between a surface of the mold and an exterior surface of the vertical members;   applying a foam into the cavities defined by the mold and between the vertical members;   curing the foam to form the insulating layer, which results in the formation of the prefabricated wall assembly; and   demolding the prefabricated wall assembly from the mold.   
     
     
         15 . A method as set forth in  claim 14  wherein the cavity defined between the mold and the vertical members includes a plurality of rib forming cavities having a depth of from about 0.5 to about 1.0 inches and said step of positioning the frame assembly is further defined as aligning the plurality of vertical members with the plurality of rib forming cavities defined by the mold. 
     
     
         16 . A method as set forth in  claim 14  wherein the cavity defined between the mold and the vertical members further includes a main cavity having a depth of from about 0.75 to about 1.5 inches and said step of applying a sprayable foam is further defined as filling the main cavity and the plurality of rib forming cavities with a sprayable foam. 
     
     
         17 . A method as set forth in  claim 14  wherein the step of assembling the frame assembly is further defined as spacing the plurality of vertical members apart from one another a distance of from about 1 to about 30 inches. 
     
     
         18 . A method as set forth in  claim 14  further comprising the step of applying a sprayable vapor retarder to the exterior surface of the insulating layer and the plurality of ribs. 
     
     
         19 . A method as set forth in  claim 14  wherein the step of applying the foam is further defined as spraying the foam into the cavities defined by the mold and between the vertical members.