MODULAR WALL PANEL ASSEMBLY

Description

FIELD

The present application relates to a modular wall panel assembly, a method of manufacturing a modular wall panel assembly and a manufacturing line for manufacturing a modular wall panel assembly.

BACKGROUND

Modular building systems are growing in prominence as they can provide an efficient, consistent and cost-effective solution for constructing buildings. For example, modular structural insulated panels (SIPs) are a high-performance building system for residential and light commercial construction. SIPs consist of an insulating foam core sandwiched between two structural facings, typically oriented strand board (OSB). SIPs are manufactured under factory-controlled conditions and can be fabricated to fit nearly any building design. The result is a building system that is strong, energy-efficient and cost-effective.

Despite recent advances, existing modular wall building systems can suffer from one or more of the following shortcomings: insulation effectiveness is limited due to thermal bridging within the wall structure; do not easily accommodate installation of mechanical elements (e.g., plumbing and electrical elements) post manufacture; have components that are susceptible to breakdown if exposed to elements; have outer surfaces that require special fixtures to support cladding; and/or are cumbersome and difficult to manufacture.

Accordingly, there is a need for a modular wall panel assembly, a method of manufacturing a modular wall panel assembly and/or a manufacturing line for manufacturing a modular wall panel assembly that can address one or more of the above noted shortcomings.

SUMMARY

In one aspect, there is provided a prefabricated wall panel comprising: a polymeric outer layer; an intermediate insulative foam layer secured to the polymer outer layer; and a frame; wherein the polymer outer layer, intermediate foam layer and frame are cooperatively configured such that the frame is partially embedded in the intermediate insulative foam layer and spaced apart from the polymer outer layer.

In another aspect, there is provided a method of manufacturing a wall panel, comprising: introducing a first liquid material into a mold; setting the first liquid material in the mold, with effect that a polymer outer layer is defined, in response to the setting of the first liquid material; introducing a second liquid material into the mold and onto the polymer outer layer; partially embedding a frame into the second liquid material such that the frame is spaced apart from the polymer outer layer; while the frame is partially embedded in the second liquid material, setting the second liquid material in the mold, with effect that: an intermediate insulative foam layer is defined, in response to the setting of the second liquid material; and the polymer outer layer and the frame are secured to the intermediate insulative foam layer, with effect that the wall panel is defined.

Other aspects will be apparent from the description and drawings provided herein.

BRIEF DESCRIPTION OF DRAWINGS

In the figures, which illustrate example embodiments,

FIG. 1 is a perspective view of a rear, inner, inward-facing, or interior side of a wall panel according to an example embodiment.

FIG. 2 is a perspective view of a front, outer, outward-facing, or exterior side of the wall panel of FIG. 1.

FIG. 3 is a rear view of the wall panel of FIG. 1.

FIG. 4 is a front view of the wall panel of FIG. 1.

FIG. 5 is a sectional view of a portion of the wall panel of FIG. 1, taken along the lines V-V of FIG. 3.

FIG. 6 is a perspective view of a portion of the wall panel of FIG. 1.

FIG. 7 is a further sectional view of a portion of the wall panel of FIG. 1.

FIG. 8 is a side view of a wall panel according to another example embodiment.

FIG. 9 is a perspective view of a rear, inner, inward-facing, or interior side of the wall panel of FIG. 8.

FIG. 10 is a further perspective view of a rear, inner, inward-facing, or interior side of the wall panel of FIG. 8.

FIG. 11 is a perspective view of a front, outer, outward-facing, or exterior side of the wall panel of FIG. 8.

DETAILED DESCRIPTION

With reference to the Figures, a wall panel 10 will be described according to example embodiments, along with a method of manufacturing the wall panel 10. In some embodiments, for example, the wall panel 10 is used as part of a modular building system in which a plurality of wall panels 10 are arranged on a supporting floor surface to provide external load bearing walls of a structure, such as a residential structure or light commercial structure. In some embodiments, for example, the wall panel 10 is a modular wall panel 10. As depicted in FIG. 1 and FIG. 2, the panel 10 has a panel length, panel height, and panel width.

In some embodiments, for example, the wall panel 10 is a prefabricated wall panel configured to support and transfer structural loads, including vertical dead and live loads from a roof and upper floors of a structure to a foundation of the structure, and further configured to support and transfer lateral loads (e.g. wind or seismic forces) to shear walls or bracing structures, in accordance with standard wood frame construction practices as governed by the Ontario Building Code (OBC), for example, OBC Part 9. The wall panel 10 is structurally load-bearing, with axial and shear load paths integrated into the prefabricated frame, such that conventional framed wall construction is replaceable by the wall panel 10 for use in residential or light commercial applications without the need for supplemental on-site framing. In some embodiments, for example, the panel 10 functions as a structural-thermal-services interface.

In some embodiments, for example, the wall panel 10 is configured to be used in typical wood construction applications, and meet Net-Zero Ready standards. In the illustrated example, the wall panel 10 includes a wood wall frame 22 that comprises a plurality of spaced-apart vertical load-bearing members 16 and secured together by a top member 18 and a bottom member 20. In some embodiments, for example, as depicted in FIG. 1 and FIG. 3, the wall panel 10 includes 11 vertical load-bearing members 16. In some embodiments, for example, as depicted in FIG. 9 and FIG. 10, the wall panel 10 includes four vertical load-bearing members 16. In some embodiments, for example, the wall panel 10 includes six vertical load-bearing members. In some embodiments, for example, as depicted in FIG. 3 and FIG. 5, for each one of the plurality of vertical load-bearing members 16, independently, the vertical load-bearing member 16 is spaced apart from an adjacent vertical load-bearing member 16 by a distance DD at most 24 inches on center, for example, in accordance with OBC Part 9, regarding wood frame housing. In some embodiments, for example, for each one of the plurality of vertical load-bearing members 16, independently, the vertical load-bearing member 16 is spaced apart from an adjacent vertical load-bearing member 16 by a distance DD of 24 inches (e.g. placed at 24-inch on center). In some embodiments, for example, for each one of the plurality of vertical members 16, independently, a material of manufacture of the vertical member 16 includes wood. In some embodiments, for example, each one of the vertical members 16, independently, is defined by a wooden member, for example, a two-by-four or 2×4 wooden member (e.g. a wooden stud). In some embodiments, for example, a material of manufacture of the top member 18 includes wood. In some embodiments, for example, the top member 18 is defined by a wooden member, for example, a two-by-four or 2×4 wooden member (e.g. a wooden stud). In some embodiments, for example, a material of manufacture of the bottom member 20 includes wood. In some embodiments, for example, the bottom member 20 is defined by a wooden member, for example, a two-by-four or 2×4 wooden member (e.g. a wooden stud). As depicted in FIG. 5 to FIG. 7, the wall frame 22 is partially embedded into a foam insulation layer 14 (e.g. an intermediate insulative foam layer 14), which, in some embodiments, for example, is continuous, which in turn is secured to a continuous polymer or polymeric sheet layer 12 (e.g. polymer or polymeric outer layer 12), as depicted in FIG. 2 and FIG. 11, which, in some embodiments, for example, is an elastomeric or elastomeric sheet layer 12 or elastomer or elastomeric outer layer 12, that forms a front, outer, outward-facing, or exterior surface 124 of the wall panel 10. In some embodiments, for example, the foam insulation layer 14 is intermediate the elastomer sheet layer 12 and a rear, inner, interior, or inward-facing surface 222 of the wall frame 22.

In some embodiments, for example, each one of the wall frame members 16, 18 and 20, independently, is sawn lumber. In some embodiments, for example, each one of the wall frame members 16, 18, and 20, independently, is Spruce-Pine-Fir (SPF) Grade No. 1, Grade No. 2, or better.

As depicted in FIG. 5, FIG. 6, and FIG. 7, in the illustrated example, a portion (e.g. a front, external, outward-facing, or exterior side portion) of the wall frame members 16, 18, 20 each are partially embedded in the foam insulation layer 14 to a depth D2, for example, in a rear, inner, interior, or inward-facing surface 142 of the foam insulation layer 14. As a result of the partial embedding the members of the wall frame 22 into the foam insulation layer 14, a portion (e.g. a rear, internal, inward-facing, or interior side portion) of the wall frame 22 protrudes inwardly from the foam insulation layer 14 by a distance D1. The inwardly protruding portion of the wall frame members 16, 18 and 20 of the wall frame 22 provide surfaces for securing an interior sheathing (e.g. drywall) to the wall frame 22, with a gap (e.g. a service cavity 24) of depth D1 being provided between a rear, inner, interior, or inward-facing surface 142 of the insulation layer 14 and a rear, inner, interior, or inward-facing surface 222 of the wall frame 22 (and also between the rear, inner, interior, or inward-facing surface 142 of the insulation layer 14 and the interior sheathing, while the interior sheathing is installed to the wall frame 22). Plumbing and electrical holes can be drilled through the inwardly protruding portions of the wall frame members 16, 18 and 20 prior to installation of interior sheathing to accommodate installation of mechanical, electrical, and plumbing components (e.g. ducts, pipes, cable trays, plumbing conduits, and electrical wiring, etc.) and other mechanical systems. In some embodiments, for example, the partial embedding of the wall frame 22 in the foam insulation layer 14 is such that a portion of the wall frame 22 extends from a rear, internal, inward-facing, or interior side 142 of the foam insulation layer 14, such that a service cavity 24 is defined between the rear, internal, inward-facing, or interior surface 142 of the foam insulation layer 14 and a rear, internal, inward-facing, or interior surface 222 of the frame 22. In some embodiments, for example, the service cavity 24 is configured to receive one or more mechanical, electrical, and plumbing components. In some embodiments, for example, the service cavity 24 has a depth of D1.

In some embodiments, for example, D1 has a value of at least 30% of the width of the vertical member 16, and at most 70% of the width of the vertical member 16. In some embodiments, for example, wherein the vertical member 16 is a two-by-four wooden member, the vertical member 16 has width of 3.5 inches and a thickness of 1.5 inches. In such embodiments, for example, D1 has a value of at least 1.05 inches and at most 2.45 inches.

In some embodiments, for example, D2 has a value of at least 30% of the width of the vertical member 16, and at most 70% of the width of the vertical member 16. In some embodiments, for example, wherein the vertical member 16 is a two-by-four wooden member, the vertical member 16 has width of 3.5 inches and a thickness of 1.5 inches. In such embodiments, for example, D2 has a value of at least 1.05 inches and at most 2.45 inches.

In some embodiments, for example, a width of the wall frame 22 is defined by a width of the wall frame members 16, 18, 20. In some embodiments, for example, a width of the wall frame 22 is defined by a width of the vertical member 16. In some embodiments, for example, the service cavity 24 has a depth D1 of at least 30% of a width of the wall frame 22, and at most 70% of the width of the wall frame. In some embodiments, for example, the wall frame 22 is partially embedded in the foam insulation layer 14 to a depth D2 of at least 30% of a width of the wall frame 22, and at most 70% of the width of the wall frame 22.

In some embodiments, for example, the sum of D1 and D2 is equal to the width of the vertical member 16. In some embodiments, for example, the sum of D1 and D2 is equal to the width of the wall frame 22.

The wall frame 22 is offset or spaced apart from a rear, inner, interior, or inward-facing surface 122 of the elastomer sheet layer 12 by a distance D3, such that direct thermal bridging between the wall frame members 16, 18 and 20 and the outer elastomer sheet layer 12 is opposed, for example, prevented, for example, absent. In some embodiments, for example, D3 has a minimum value of at least 0.25 inches.

In some embodiments, for example, the wall panel 10 is manufactured by providing a pan or mold (not shown) that conforms to the outer dimensions of the wall panel 10. For example, for an eight-foot by 20-foot wall panel 10, a horizontally oriented mold that can accommodate an eight-foot by 20-foot wall preassembled wall frame 22 can be provided. A first material is introduced in liquid form (e.g. pouring the liquid) into the mold to provide an eight-foot by 20-foot layer of material that, when fully set, defines (e.g. forms) elastomer sheet layer 12. The amount of the first material that is poured into the mold is based at least in part on the desired thickness or width of the elastomer sheet layer 12 and the size of the pan or mold. After the first material is introduced into the mold, the first material is set, with effect that the elastomer sheet layer 12 is defined, in response to the setting of the first liquid material. After the elastomer sheet layer 12 is defined, a second material is introduced into the mold in liquid form (e.g. pouring the liquid on top of the elastomer sheet layer 12) to provide a further eight-foot by 20-foot layer of material that, when fully set, defines (e.g. forms) foam insulation layer 14. The amount of the second material that is poured into the mold is based at least in part on the desired values of D1, D2, and D3, and the size of the pan or mold. Prior to setting of the second material that forms foam insulation layer 14, pre-assembled wall frame 22 is placed onto the second material such that it will embed into the second material to depth D2, but still remain offset from a rear, inner, interior, or inward-facing surface 122 of the elastomer sheet layer 12. At this point, while the wall frame 22 is partially embedded in the second liquid material, the second liquid material is set in the mold, with effect that: the intermediate insulative foam layer 14 is defined, in response to the setting of the second liquid material, and the elastomer sheet layer 12 and the frame 22 are secured to the intermediate insulative foam layer 14, with effect that the wall panel 10 is defined. After the second material is set and the wall panel 10 is defined, the wall panel 10 can be removed from the mold. The foam insulation layer 14 and elastomer sheet layer 12 are adhesively bonded to each other through the interaction of their respective materials during the setting process. Similarly, the members 16, 18 and 20 of the wall frame 22 are rigidly secured in place to the foam insulation layer 14 by adhesive bonds resulting from the setting process.

The resulting wall panel 10 has a rigid, waterproof outer surface, interior frame members for securing an interior finishing material to, and an intervening insulative layer, with space provided for running plumbing and electrical and other mechanical components. In some embodiments, for example, the foam insulation layer 14, the elastomer sheet layer 12, and the wall frame 22, which are secured together to define the wall panel 10, are co-operatively configured to define axial and shear load paths and support and transfer structural loads, including vertical dead and live loads from roof and upper floors of a structure to the foundation of the structure, and lateral loads (e.g., wind or seismic forces) to shear walls or bracing structures, in accordance with standard wood frame construction practices governed by the OBC Part 9, such that the wall panel 10 is a load-bearing wall-panel.

In some embodiments, for example, the manufacturing of the panel 10 is effectuated automatically. In some embodiments, for example, after the first material is introduced into the mold, the first material is set. After the first material is set (e.g. via detection of the setting by a sensor) such that the elastomer sheet layer 12 is defined, the second material is introduced into the mold on top of the elastomer sheet layer 12. Prior to setting of the second material, the wall frame 22 is partially embedded in the second material, for example, by a mechanical apparatus, such that the partial embedding of the wall frame 22 in the second material is controlled. After the second material is set (e.g. via detection of the setting by a sensor) such that the foam insulation layer 14 is defined, the wall panel 10 is defined, and can be removed by the mold, for example, by a mechanical apparatus. In some embodiments, for example, wherein the manufacturing of the panel 10 is effectuated automatically, the process is controlled and sequenced automatically, and can have automation-ready tolerances.

In some embodiments, for example, the manufacturing of the wall panel 10 can have alternative sequencing.

In some embodiments, for example, the partial embedding of the wall frame 22 in the foam insulation layer 14 is uniform.

In some embodiments, for example, the partial embedding of the wall frame 22 in the foam insulation layer 14 is non-uniform. In this respect, in some embodiments, for example, a first portion of the frame 22 is partially embedded in the foam insulation layer 14 at a first depth, and a second portion of the frame 22 is partially embedded in the foam insulation layer 14 at a second depth, wherein the first depth and the second depth are different.

In some embodiments, for example, the material used for foam insulation layer 14 is a high R value continuous foam that is configured to achieve a three quarter external to one quarter internal insulation matrix and an effective R-value of at least R-25, for example, at least R-30. In one example, the material used for foam insulation layer 14 provides two pounds of foam at five inches thick.

In some embodiments, for example, the foam insulation layer 14 has a compressive strength of at least 16 pounds per square inch, for example, at least 18 pounds per square inch, for example, at least 20 pounds per square inch, in accordance with OBC Supplementary Standard SB-12.

In some embodiments, for example, the foam insulation layer 14 has a flame spread index of less than 500 if exposed to flame, in accordance with CAN/ULC-S705.1 and CAN/ULC-S124.

In some embodiments, for example, the foam insulation layer 14 is defined by a mixture of resin and isocyanate. In some embodiments, for example, the resin has a Brookfield viscosity 30 RPM of 940 cps at 72° F., specific gravity of 1.23, storage temperature of 40° F.-85° F., and has a shelf life of six months. In some embodiments, for example, the resin has a density of 8.67+/−0.5 pounds/gallon. In some embodiments, for example, the resin has a viscosity of 1020 cps at 77° F. In some embodiments, for example, the resin is UL FG 220 Resin, available from Ultimate Linings. In some embodiments, for example, the isocyanate has a Brookfield viscosity 30 RPM of 200 cps at 72° F., specific gravity of 1.24, storage temperature of 40° F.-85° F., and has a shelf life of 24 months. In some embodiments, for example, the isocyanate has a density of 9.67+/−0.5 pounds/gallon. In some embodiments, for example, the isocyanate has a viscosity of 630 cps at 77° F. In some embodiments, for example, the isocyanate is UL FG 220 Isocyanate, available from Ultimate Linings.

In some embodiments, for example, the foam mixture of resin and isocyanate has a density of 9.17 pounds per gallon.

In some embodiments, for example, the mix ratio of the resin and isocyanate of the foam insulation layer 14 is one to one by weight (e.g. 100 parts resin to 100 parts isocyanate). In some embodiments, for example, the mix ratio of the resin and isocyanate of the foam insulation layer 14 is one to one by volume.

In some embodiments, for example, the resin and the isocyanate is to be preconditioned between 70° F. to 90° F. (21° C. to 32° C.) before application. In some embodiments, for example, the mold is to be disposed at a temperature of 95° F. to 125° F. (35° C. to 51.67° C.) before application. In some embodiments, for example, the foam insulation layer 14 is applied using a high pressure, plural component, heated, 1:1 by volume, spray equipment with 2,000 psi fluid pressure capability. In some embodiments, for example, the foam insulation layer 14, the resin and the isocyanate, should be heated between 140° F. to 160° F. (60° C. to 71° C.). In some embodiments, for example, the spray equipment is to generate adequate fluid pressure for proper mixing of the resin and isocyanate to effectuate desired polymerization results.

In some embodiments, for example, the foam mixture of resin and isocyanate has a cream time of 23 seconds, gel time of 140 seconds, tack free time of 190 seconds, rise time of 225 seconds, and free rise core density of 2.19 pcf.

In some embodiments, for example, the foam mixture of resin and isocyanate has a gel time of two to four seconds, and a tack free time of 10 to 20 seconds.

In some embodiments, for example, the foam insulation layer 14 has a density (e.g. free rise density) of 2.0 pcf, in accordance with ASTM D-1622. In some embodiments, for example, the foam insulation layer 14 has a compressive strength (parallel) of 25 psi, and a compressive strength (perpendicular) of 14 psi, in accordance with ASTM D-1621. In some embodiments, for example, the foam insulation layer 14 has an initial k-factor of 0.16 Btu*in/(hr*ft²*° F.), in accordance with ASTM C-518. In some embodiments, for example, the foam insulation layer 14 has a closed cell content of greater than 90%. In some embodiments, for example, the foam insulation layer 14 has dimensional stability, at 28 days aging, of +8.2% volume change (heat age at 200° F.), of 0.1% volume change (freezer at −20° F.), and of +11.9% (humidity aging at 100% RH, 158° F.). In some embodiments, for example, the foam insulation layer 14 has a maximum service temperature of 180° F. In some embodiments, for example, the foam insulation layer 14 has a flame spready index of 25, and a smoke index of less than 450, for example, a smoke index of 250, in accordance with ASTM E-84.

In some embodiments, for example, the foam insulation layer 14 has a density of 62+1 lbs./ft³. In some embodiments, for example, the foam insulation layer 14 has an elongation of 200+20%, in accordance with ASTM D412. In some embodiments, for example, the foam insulation layer 14 has tensile strength of 2700±300 psi, in accordance with ASTM D412. In some embodiments, for example, the foam insulation layer 14 has hardness shore D of 55±5, in accordance with ASTM D2240. In some embodiments, for example, the foam insulation layer 14 has tear strength of 400±40 lbs/in, in accordance with ASTM D624. In some embodiments, for example, the foam insulation layer 14 has taber abrasion (mg loss/1000 cycles) of 20.67 mg, in accordance with ASTM D4060, using a CS-17 wheel (1000 g load). In some embodiments, for example, the foam insulation layer 14 has safe walking surfaces of 0.99 (dry) and 0.95 (wet), in accordance with ASTM F1637.95. In some embodiments, for example, the foam insulation layer 14 has coefficient of friction of 1.55 (static) and 1.35 (kinetic), in accordance with ASTM D1894. In some embodiments, for example, the foam insulation layer 14 passes the flammability of interior materials test, in accordance with FMVSS302. In some embodiments, for example, the foam insulation layer 14 has impact resistance of 320 inch pounds with no failure, in accordance with ASTM D2794. In some embodiments, for example, the foam insulation layer 14 has stone chip resistance rating of 10, in accordance with SAE J400. In some embodiments, for example, the foam insulation layer 14 has Poisson's Ratio of 0.47 and Precision Modulus of 19.38, in accordance with ASTM E132. In some embodiments, for example, the foam insulation layer 14 has a glass transition temperature of −49.2° C. based on a dynamic mechanical analysis test (Loss Modulus, E″ Tg), in accordance with ASTM E1640. In some embodiments, for example, the foam insulation layer 14 has a dielectric strength of 370 volts/mil, in accordance with ASTM D149. In some embodiments, for example, the foam insulation layer 14 has a dielectric constant of 7.40, in accordance with ASTM D150. In some embodiments, for example, the foam insulation layer 14 has a dissipation factor of 0.055, in accordance with ASTM D150.

In some embodiments, for example, the foam insulation layer 14 is defined by UL FG 220 pour-in-place foam, available from Ultimate Linings. In some embodiments, for example, the foam insulation layer 14 is defined by UL XT-66 spray foam, available from Ultimate Linings.

In some embodiments, for example, the insulation layer 14 comprises foamed or cast insulating material.

In some embodiments, for example, the elastomer sheet layer 12 forms a continuous elastomer outer layer that is sufficiently rigid, strong, and durable, such that cladding can be attached directly to the wall panel assembly. In some embodiments, for example, the elastomer sheet layer 12 defines a final outer, exterior, or outward-facing surface 104 of the panel 10 without cladding. In some embodiments, for example, a surface of the pan or mold used in the manufacturing process, on which the first liquid material is poured and is cured to define the elastomer sheet layer 12, includes a patterned surface for application of an impression on the outer, exterior, or outward-facing surface 124 of the elastomer sheet layer 12 to create an appear that simulates a material, for example, a simulated wood or brick appearance. In some embodiments, for example, the material used for elastomer sheet layer 12 provides 1.4 lbs of elastomer at 0.25 inches thick. By way of reference, in some embodiments, for example, the weight per area of the elastomer sheet layer 12 having a 0.125 inch thickness is 3.1531 kg/m². In some embodiments, for example, the weight per area of the elastomer sheet layer 12 having a 0.25 inch thickness is 6.2983 kg/m². In some embodiments, for example, the elastomer sheet layer 12 has a thickness having a minimum value of at least 0.100 inches.

In some embodiments, for example, the elastomer sheet layer 12 has a flame spread index of less than 500 if exposed to flame, in accordance with CAN/ULC-S705.1 and CAN/ULC-S124.

In some embodiments, for example, the material of manufacture of the elastomer sheet layer 12 includes polyurethane. In some embodiments, for example, the elastomer sheet layer 12 is a polyurethane sheet layer.

By way of non-limiting examples: in some embodiments, for example, elastomer sheet layer 12 is 0.125 inches thick. In some embodiments, for example, the elastomer sheet layer 12 is 0.25 inches thick. In some embodiments, for example, the foam insulation layer 14 is at least five inches thick. In some embodiments, for example, the wall panel 10 has a complete width or depth from an inner surface 222 (e.g. inner, interior, or inward-facing surface 222) of the fame 22 to an outer surface 124 (e.g. outer, exterior, or outward-facing surface 124) of the elastomer sheet layer 12 of 6¾ inches. In some embodiments, for example, frame members 16, 18, 20 are wood two-by-fours or 2×4s (e.g., 1.5 inches thickness by 3.5 inches width). In some embodiments, for example, D1=D2=1.75 inches and D3=3.25 inches. In some embodiments, for example, frame members 16, 18, 20 are wood two-by-sixes or 2×6s (e.g., 1.5 inches thickness by 5.5 inches width). In some embodiments, for example, frame members 16, 18, 20 are wood two-by-eights or 2×8s (e.g., 1.5 inches thickness by 7.25 inches width). In some embodiments, for example, the dimensions of the frame members 16, 18, 20 (e.g. length, width, thickness) are chosen based on the weight and load that the wall panel 10 is expected to bear. In some embodiments, for example, frame members 16, 18, 20 are formed from rigid materials other than wood. In some embodiments, for example, frame members 18 are spaced apart at spacing other than 24 inches on center.

All dimensions are non-limiting examples and subject to manufacturing tolerances. Numerous alternative dimensional configurations are possible.

In some embodiments, for example, the wall panel frame 222 can be dimensioned other than 20 feet wide by 8 feet high, such as 40 feet by 10 feet. In some embodiments, for example, door and window cutouts and framing can be included in the pre-assembled framing and the pan/mold shaped to exclude the first and second materials from the window and door locations during the wall panel forming process.

In some embodiments, for example, the wall panel system disclosed herein can reduce development time, reduce material waste, and improve energy efficiency of homes, and provide a NetZero-ready wall.

In some embodiments, for example, a manufacturing line is provided that can output a pre-fabricated wood framed wall panel (e.g. wall panel 10) which utilizes liquid foam poured onto an exterior wall layer, and a wall frame 22 that is partially embedded in the insulation layer 14 that is defined in response to setting of the liquid foam poured onto the exterior wall layer, such that a space (e.g. a vapour gap or air gap; service cavity 24) is defined between the inward-facing surface 222 of the wall frame 22 and the inward-facing surface 142 of the insulation layer 14, while also providing a rigid exterior wall surface 124 to which exterior cladding can be affixed. In some embodiments, for example, automated tooling is used to mass produce panels eight to 10 feet high×20 feet in length that can be shipped directly to a build site where they will be boomed in and placed into the correct orientation. In some examples, plumbing and electrical holes are pre-drilled before the wall panels leave the manufacturing site which can save construction time and increase productivity.

A liquid, which, when set, defines the insulation layer 14, will be poured on the exterior wall layer 12 of the panel 10, and the wall frame 22 is partially embedded in the liquid that sets to define the insulation layer 14, which, after the liquid is set, leaves an air gap, having a thickness or depth of D1, between the inward-facing surface 142 of the insulation layer 14 and the inward-facing surface 222 of the wall frame 22, on the side of the wall panel 10 that faces the interior of the house. In some embodiments, for example, while sheathing (e.g. drywall) is mounded to the wall frame 22, a vapour barrier is defined between the sheathing and the interior-facing surface of the insulation layer 14, and, in some applications, the defined vapour barrier reduces the amount of energy required to heat and cool the home, for example, by at least 30%. In some embodiments, for example, the panel 10 is configured to provide an effective R-value of at least R-25. In some embodiments, for example, the panel 10 is configured to provide an effective R-value of at least R-30. In some embodiments, for example, the R-value of the panel 10 aligns with Net Zero Ready under Tier 3-4 energy compliance pathways.

In some embodiments, for example, using conventional building techniques, it usually takes between two to three weeks to frame a house, whereas, in some embodiments, for example, the panel 10 can be constructed in three days. In addition, using conventional techniques, it currently takes three to four days to insulate a house. In some embodiments, for example, the time to insulate a house is reduced to one day using the described wall panel system as the only insulation that will need to be done onsite is blowing in the fiberglass loose fill in the ceiling cavity once the roof is put on.

The one example, a manufacturing process comprises of four main subsystems—the wall framing subsystem, the sub-component sub assembly cell, the insulation/sheathing dispenser and application subsystem, and the semi-automated saw subsystem.

The wall framing subsystem consists of a 2×4 unloader that will unload layers of 2×4 bundles and escape each board one at a time, a nailing station that will locate, crowd, and nail the studs to the top and bottom members, a wall frame extruder which will index the wall frame to the for the correct stud location, and a buffer conveyor for walls to transfer out of the station.

The sub-component sub assembly cell includes automated sub assembly stations for door frames, window frames, etc. that will assemble door and wall sub-assemblies.

The insulation/sheathing dispenser and application subsystem consists of two (2) stations, each with a servo adjustable tray for different wall heights and lengths. In some embodiments, for example, robotics dispense the insulation and sheathing material onto an operator-installed, disposable tray liner. In some embodiments, for example, the wood wall frame 22 is manually loaded onto the insulation and sheathing material for bonding, and the completed wall panel section 10 can be removed manually. One (1) station can be prepared and unloaded while the other is operation.

The semi-automated saw subsystem is a fully enclosed cutting center that keeps the operator clear of dust and moving parts. In some embodiments, for example, the semi-automated saw subsystem is a 20.5″ custom saw subsystem that has: configurable material flow, an Inkjet printer for board marking before reaching the saw blade, intuitive, easy-to-use nesting cutting software, and it is manually loaded with an automated live deck.

In some embodiments, for example, the dimensions, materials, material properties, compositions, performance characteristics, and thicknesses or widths of the wall panel 10 as described herein are provided as examples. Actual implementations can be varied, selected. and optimized based on structural, thermal, moisture, hygrothermal, acoustic, fire, or other performance criteria, or regulatory requirements, without departing from the scope of the invention.

The preceding discussion provides many example embodiments. Although each embodiment represents a single combination of inventive elements, other examples may include all suitable combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, other remaining combinations of A, B, C, or D, may also be used.

The term “connected” or “coupled to” may include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements).

Although the embodiments have been described in detail, it should be understood that various changes, substitutions and alterations could be made herein.

Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

As can be understood, the examples described above and illustrated are intended to be examples only. The invention is defined by the appended claims.