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 method of producing a wall section, the method comprising:
 providing a first set of substantially parallel supports;   providing a second set of substantially parallel supports disposed substantially perpendicular to said first set;   applying a covering to one side of said supports, said covering and said sets of supports defining two or more cavities; and,   downwardly injecting a curable flowable material into one or more of said cavities in the form of a plurality of beads in a predefined path comprising both a first direction, and a second direction substantially perpendicular to said first direction, while said supports are in a horizontal position.   
     
     
         2 . The method of  claim 1 , further comprising applying a second covering to a second side of said supports that is opposite to said first side of said supports. 
     
     
         3 . The method of  claim 1 , wherein said curable flowable material adheres to both said first covering and said supports such that said covering is adhered to said supports by said curable flowable material. 
     
     
         4 . The method of  claim 1 , wherein said covering is drywall. 
     
     
         5 . The method of  claim 1 , wherein said supports are made from wood. 
     
     
         6 . The method of  claim 1 , wherein said supports are made from metal. 
     
     
         7 . The method of  claim 1 , wherein said curable flowable material is closed cell foam. 
     
     
         8 . The method of  claim 1 , wherein when said curable flowable material cures a torsional and tensional rigidity of said wall section is increased thereby. 
     
     
         9 . The method of  claim 1 , wherein when said curable cures, the insulation factor of said wall section is increased thereby. 
     
     
         10 . The method of  claim 1 , wherein when said curable flowable material cures, at least a partial vapour barrier from one side of said wall section to the other side of said wall section is provided thereby.