Prefabricated wall panel

Claim 1

A prefabricated load bearing wall panel for constructing the walls of a building comprising: (a) at least two vertical support members in parallel spaced relationship, each of said vertical members including at least one longitudinal flange projecting generally inward toward the opposite vertical member; (b) a first horizontal support member attached between the upper ends of said vertical support members, a second horizontal support member disposed parallel to said first member and secured to said vertical members, the first and second horizontal members defining a general rectangular framework enclosing a space therebetween, said second horizontal support member is secured to said vertical members intermediate the ends of the latter to define vertical legs extending beyond said framework for securing said wall panel to the building; and (c) a light-weight, rigid foam insulating panel integrally molded to said vertical support members and said flanges substantially filling the space enclosed by said framework, said foam panel comprising a liquid foam which adheres to said vertical members and said flanges, said foam solidifying to form a self-supporting panel defining first and second faces of solidified foam.

Claim 11

A method for manufacturing a prefabricated load bearing wall panel for constructing the walls of a building comprising the steps of: (a) forming a framework having two vertical support members in spaced parallel relationship secured together by first and second horizontal support members, each of said vertical members having an inwardly projecting flange; (b) positioning two mold forming plates across said vertical members in opposing relationship enclosing at least a length of both vertical members, said mold forming plates and said vertical support members defining therebetween a mold forming compartment; (c) injecting into said mold forming compartment foam in a liquid state which expands to fill said compartment and solidifies to form a rigid, light-weight foam panel, said foam panel adhering to the vertical support members and said flanges; and (d) removing the two mold forming plates from said frame after the foam has substantially solidified such that a foam panel is formed having self-supporting foam faces, whereby a wall panel having an integrally molded foam panel is prefabricated, (e) placing a sheet of material between said framework and one of said mold forming plates prior to step (c), said sheet not being mounted to said framework, said sheet held only by the adhesiveness of said foam to the face of the foam panel, said sheet serving as a mold releasing element to prevent said foam from adhering to said one mold framing plate.

Claim 12

A method for manufacturing a prefabricated load bearing wall panel for constructing the walls of a building comprising the steps of: (a) forming a framework having two vertical support members in spaced parallel relationship secured together by first and second horizontal support members, each of said vertical members having an inwardly projecting flange; (b) positioning two mold forming plates across said vertical members in opposing relationship enclosing at least a length of both vertical members, said mold forming plates and said vertical support members defining therebetween a mold forming compartment; (c) injecting into said mold forming compartment foam in a liquid state which expands to fill said compartment and solidifies to form a rigid, light-weight foam panel, said foam panel adhering to the vertical support members and said flanges; and (d) removing the two mold forming plates from said frame after the foam has substantially solidified such that a foam panel is formed having self-supporting foam faces, whereby a wall panel having an integrally molded foam panel is prefabricated, (e) placing a sheet of material between said framework and one of said mold forming plates prior to step (c), said sheet not being mounted to said framework, said sheet held only by the adhesiveness of said foam to the face of the foam panel, said sheet serving as a mold releasing element to prevent said foam from adhering to said one mold framing plate.