Abstract: Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

Abstract: Methods for manufacturing foam wall structures are described. The methods include placing a wall structure proximate to a robotic arm, orienting an imaging device so that the imaging device on the robotic arm faces a cavity in the wall structure, surveying the cavity using the imaging device, determining a spray foaming pattern to fill the cavity to a selected depth with a foam layer, orienting the spray nozzle so the spray nozzle faces the cavity, and spray-applying the foam-forming composition into the cavity to the selected depth by passing the foam-forming composition through the spray nozzle to form the foam layer. Foam wall structure manufacturing systems that are suitable for carrying out such methods are also described.

Abstract: Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

Abstract: Foam wall structures and methods for making them are described. The wall structures include a frame, a mesh mechanically fastened to a front surface of the frame, a foam panel at least partially abutting and overlying the mesh, and a foam layer disposed in a cavity defined by the frame, the mesh, and the foam panel. Buildings that include such wall structures are also described.

Abstract: Wall structures and methods of manufacturing wall structures are described. The wall structures include a frame, a foam panel attached to the frame, a brace disposed in a cavity defined by the frame, and a foam layer. The wall structures can impart a high wall racking strength and good thermal performance through the combination of the foam layer, brace, and the foam panels.

Abstract: Foam wall structures and methods for making them are described. The wall structures include a frame, a sheet metal sheathing overlying a front surface of the frame, a foam panel overlying the sheet metal sheathing, and a foam layer disposed in a cavity defined by the frame and the sheet metal sheathing. Buildings that include such wall structures are also described.

Abstract: Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

Abstract: Foam wall structures and methods for making foam wall structures. The wall structures include a frame, a foam panel overlying a front surface of the frame, a first foam layer disposed in a cavity defined by the frame and the foam panel, in which the first foam layer self-adheres to one or more members of the frame, and a second foam layer disposed in the cavity. The second foam layer self-adheres to the first foam layer and has a density that is less than the density of the first foam layer.

Abstract: Foam wall structures and methods for making them are described. The wall structures include a frame, a mesh mechanically fastened to a front surface of the frame, a foam panel at least partially abutting and overlying the mesh, and a foam layer disposed in a cavity defined by the frame, the mesh, and the foam panel. Buildings that include such wall structures are also described.

Abstract: Methods for manufacturing foam wall structures are described. The methods include placing a wall structure proximate to a robotic arm, orienting an imaging device so that the imaging device on the robotic arm faces a cavity in the wall structure, surveying the cavity using the imaging device, determining a spray foaming pattern to fill the cavity to a selected depth with a foam layer, orienting the spray nozzle so the spray nozzle faces the cavity, and spray-applying the foam-forming composition into the cavity to the selected depth by passing the foam-forming composition through the spray nozzle to form the foam layer. Foam wall structure manufacturing systems that are suitable for carrying out such methods are also described.

Abstract: Wall structures and methods of manufacturing wall structures are described. The wall structures include a frame, a foam panel attached to the frame, a brace disposed in a cavity defined by the frame, and a foam layer. The wall structures can impart a high wall racking strength and good thermal performance through the combination of the foam layer, brace, and the foam panels.

Abstract: Prefabricated insulated floor assemblies, methods for manufacturing such assemblies, and use of these floor assemblies in a building are described. The assemblies include a sheathing panel, I-joists, and rigid foam insulation boards positioned in a cavity formed by the sheathing panel and the I-joists.

Abstract: Prefabricated insulated floor assemblies, methods for manufacturing such assemblies, and use of these floor assemblies in a building are described. The assemblies include a sheathing panel, I-joists, and rigid foam insulation boards positioned in a cavity formed by the sheathing panel and the I-joists.

Abstract: Insulated buildings are described. The building include: (a) a sloped roof that is a prefabricated insulated roof assembly; (b) a generally horizontally arranged flooring assembly having an end that is arranged over a wall structure and under the sloped roof assembly; (c) a sloped member that is arranged over the end of the flooring assembly that is over the wall structure, and (d) a rigid foam insulation member arranged in the cavity of the roof assembly so as to bridge a lower surface of a rigid foam insulation board in the roof assembly to the sloped member.

Abstract: Insulated buildings are described. The building include: (a) a sloped roof that is a prefabricated insulated roof assembly; (b) a generally horizontally arranged flooring assembly having an end that is arranged over a wall structure and under the sloped roof assembly; (c) a sloped member that is arranged over the end of the flooring assembly that is over the wall structure, and (d) a rigid foam insulation member arranged in the cavity of the roof assembly so as to bridge a lower surface of a rigid foam insulation board in the roof assembly to the sloped member.

Abstract: Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

Abstract: Prefabricated insulated roof assemblies, methods for manufacturing such assemblies, and use of these roof assemblies in a building are described. The assemblies include a sheathing panel comprising an inset solar panel, I-joists, and a rigid foam insulation board positioned in a cavity formed by the sheathing panel and the I-joists.

Abstract: Prefabricated insulated roof assemblies, methods for manufacturing such assemblies, and use of these roof assemblies in a building are described. The assemblies include a sheathing panel, I-joists, and rigid foam insulation boards positioned in a cavity formed by the sheathing panel and the I-joists.

Abstract: Disclosed are compositions that comprise water and a polyether polyol derived from sucrose and an alkylene oxide, as well as polyurethane foam systems comprising such compositions, methods for their production, and the resulting polyurethane foams.

Abstract: Methods of manufacturing wall structures having high racking strength are described in this specification. The methods include spray applying a foam-forming composition into a cavity of a wall structure, wherein the wall structure is disposed in a climate-controlled spray application station and allowing the foam-forming material to expand within at least a portion of the cavity to form a foam layer deposited in the cavity. In the methods, the foam layer is formed in-situ during the manufacturing method, and the density of the foam layer is selected and the relative humidity and dew point of the air in the climate-controlled spray application station throughout the spray applying is selected so that the wall structure has a racking strength of at least 500 pounds per linear foot.