US 11,905,707 B2
Foam wall structures and methods for their manufacture
Eric C. Giles, Pittsburgh, PA (US)
Assigned to Covestro LLC, Pittsburgh, PA (US)
Filed by Covestro LLC, Pittsburgh, PA (US)
Filed on Jun. 29, 2021, as Appl. No. 17/361,957.
Prior Publication US 2022/0412081 A1, Dec. 29, 2022
Int. Cl. E04B 2/84 (2006.01); C08G 18/18 (2006.01); C08G 18/20 (2006.01); C08G 18/24 (2006.01); C08G 18/42 (2006.01); C08G 18/72 (2006.01); C08J 9/14 (2006.01)
CPC E04B 2/847 (2013.01) [C08G 18/1808 (2013.01); C08G 18/1825 (2013.01); C08G 18/2027 (2013.01); C08G 18/242 (2013.01); C08G 18/4219 (2013.01); C08G 18/72 (2013.01); C08J 9/148 (2013.01); C08G 2110/0058 (2021.01); C08J 2203/10 (2013.01); C08J 2203/164 (2013.01); C08J 2375/04 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A wall structure comprising:
(a) a frame 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 overlying the front frame surface, wherein at least one of: (i) the foam panel abuts the front frame surface such that the foam panel, the first member, the second member, and the connecting members define a cavity, or (ii) a non-foam sheathing abuts the front frame surface between the front frame surface and the foam panel, such that the non-foam sheathing, the first member, the second member, and the connecting members define the cavity; and
(c) a polyurethane foam layer disposed within the cavity, wherein the polyurethane foam layer:
(i) adheres to a rear surface of at least one of the foam panel or, if present, a rear surface of the non-foam sheathing,
(ii) has a density, as determined by ASTM D1622-14, of 44 kg/m3 (2.75 lb/ft3) to 160 kg/m3 (10.0 lb/ft3) and exhibits a Class A rating according to ASTM E84-16, and
(iii) is a cured reaction product of a polyurethane foam-forming composition comprising:
(1) a polyisocyanate present in an amount by weight;
(2) an aromatic polyester polyol having a functionality of greater than 2.5 and an OH number of 300 to 400 mg KOH/g, which is present in an amount of at least 50% by weight, based on total weight of the polyurethane foam-forming composition less the weight of the polyisocyanate;
(3) a catalyst; and
(4) a blowing agent composition comprising water and a hydrofluoroolefin, wherein the hydrofluoroolefin is present in an amount of 1 to 6% by weight, based on the total weight of the polyurethane foam-forming composition, less the weight of the polyisocyanate.