US 11,718,989 B2
Modified foam wall structures with high racking strength and methods for their manufacture
David M. Baily, Upper Saint Clair, PA (US); James L. Lambach, McMurray, PA (US); and Michael F. Palmosina, II, Baden, PA (US)
Assigned to Covestro LLC, Pittsburgh, PA (US)
Filed by Covestro LLC, Pittsburgh, PA (US)
Filed on Sep. 22, 2021, as Appl. No. 17/481,523.
Application 17/481,523 is a continuation of application No. 16/151,492, filed on Oct. 4, 2018, granted, now 11,519,172.
Prior Publication US 2022/0002998 A1, Jan. 6, 2022
Int. Cl. E04C 2/38 (2006.01); E04B 1/26 (2006.01); E04B 1/343 (2006.01); E04B 1/74 (2006.01); E04B 2/56 (2006.01); E04B 1/38 (2006.01)
CPC E04C 2/386 (2013.01) [E04B 1/26 (2013.01); E04B 1/34321 (2013.01); E04B 1/74 (2013.01); E04B 2/562 (2013.01); E04B 2001/386 (2013.01); E04B 2103/04 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method for modifying a foam wall structure comprising:
(a) frame members comprising:
(i) a first member;
(ii) a second member spaced apart from the first member; and
(iii) connecting members extending between the first member and the second member, wherein the first member, the second member, and the connecting members each comprise a front surface and a rear surface that form a front frame surface and a rear frame surface;
(b) a foam panel attached to the front frame surface, wherein:
(i) the foam panel overlies the front frame surface; and
(ii) the foam panel, the first member, the second member, and the connecting members define a cavity; and
(c) a spray-applied polyurethane foam layer disposed within the cavity and on a surface of the first member, the second member, and the connecting members and adhered to the foam panel,
wherein the method comprises depositing a high solids-containing, chemically-curing, and non-foaming liquid polymeric structural adhesive composition into at least one of (A) an aperture located within the spray-applied polyurethane foam layer, and (B) an aperture located between the spray-applied polyurethane foam layer and at least one of the frame members.