Wall fabrication system and method

Abstract

A wall fabrication system and method is provided. In an embodiment, an assembly line comprises one or framing stations and one or more insulation stations. The frame stations are configured to build a wall frame consisting of wall studs and a covering such as drywall. The wall studs and drywall define cavities in the frame which are to be insulated. Optionally, mechanical components such as electrical and plumbing can be installed. The wall section is then transferred to the insulation station. The insulation station is configured to fill the cavities in the wall frame with closed cell foam which is injected in flowable form into each cavity.

1 . A wall section comprising:
 a first set of substantially parallel supports;   a second set of substantially parallel supports disposed substantially perpendicular to said first set;   a covering applied to one side of said supports;   said covering and said sets of supports defining cavities; and,   a curable flowable material downwardly injected into one or more of said cavities while said supports are in a horizontal position.   
   
   
       2 . The wall section of  claim 1  further comprising a second covering applied to a second side of said supports that is opposite to said first side of said supports. 
   
   
       3 . The wall section of  claim 1  wherein said foam material adheres to both said first covering and said supports such that said covering is adhered to said supports by said foam material. 
   
   
       4 . The wall section of  claim 1  wherein said covering is drywall. 
   
   
       5 . The wall section of  claim 1  wherein said supports are made from wood. 
   
   
       6 . The wall section of  claim 1  wherein said supports are made from metal. 
   
   
       7 . The wall section of  claim 1  wherein said flowable material is closed cell foam. 
   
   
       8 . The wall section of  claim 1  wherein when said flowable material cures a torsional and tensional rigidity of said wall section is increased thereby. 
   
   
       9 . The wall section of  claim 1  wherein when said flowable material increases the insulation factor of said wall section. 
   
   
       10 . The wall section of  claim 1  wherein when said flowable material provides at least a partial vapour barrier from one side of said wall section to the other side of said wall section. 
   
   
       11 . A method of insulating a wall section of a site-built home; said wall section comprising a first set of substantially parallel supports; a second set of substantially parallel supports disposed substantially perpendicular to said first set; a covering positioned on one side of said supports;
 said covering and said sets of supports defining cavities; the method comprising:   orienting said wall section horizontally such that said cavities face upwards; and,   injecting curable flowable material downwardly into one or more of said cavities.   
   
   
       12 . The method of  claim 11  wherein further comprising applying a second covering to a second side of said supports that is opposite to said first side of said supports. 
   
   
       13 . The method of  claim 11  wherein said foam material is applied to both said first covering and portions of said supports that are perpendicular to said first covering and further comprising the step of:
 waiting until said foam material cures such that said covering is adhered to said supports.   
   
   
       14 . The method of  claim 11  wherein said covering is drywall. 
   
   
       15 . The method of  claim 11  wherein said supports are made from wood. 
   
   
       16 . The method of  claim 11  wherein said supports are made from metal. 
   
   
       17 . The method of  claim 11  wherein said curable material is closed cell foam. 
   
   
       18 . The method of  claim 11  wherein when said curable flowable material is selected such that when said flowable material cures a torsional and tensional rigidity of said wall section is increased thereby. 
   
   
       19 . The method of  claim 11  wherein said curable flowable material is selected such that when said flowable material cures said material increases the insulation factor of said wall section. 
   
   
       20 . The method of  claim 11  wherein said curable flowable material is selected so as to provide at least a partial vapour barrier from one side of said wall section to the other side of said wall section when said. 
   
   
       21 . A system for manufacturing a wall section comprising:
 one or more framing stations for producing wall sections that comprise a first set of substantially parallel supports; a second set of substantially parallel supports disposed substantially perpendicular to said first set; a covering applied to one side of said supports;   said covering and said sets of supports defining cavities;   one or more insulation stations for receiving wall sections from said framing stations and for injecting a curable flowable material downwardly into one or more of said cavities while said supports are in a horizontal position.   
   
   
       22 . The system of  claim 21  wherein said framing stations and said insulation stations are configured to produce and insulate, respectively, wall sections that have different configurations. 
   
   
       23 . The system of  claim 22  further comprising automation equipment for said framing stations and said insulation stations. 
   
   
       24 . The system of  claim 23  further comprising a computer configured to control said automation equipment in said framing stations and said insulation stations according to a production schedule in order to continuously produce and insulate a plurality of wall sections having different configurations. 
   
   
       25 . The system of  claim 21  wherein said covering is an inside wall of a home. 
   
   
       26 . The system of  claim 21  wherein said covering is an outside wall of a home