Modular wall panels having a frame of a plurality of frame components and at least one wall sheet affixed to the frame. Each frame component includes an outer surface with at least one aperture configured to receive and retain an insert therein. The apertures are also configured to permit a cable(s) to pass therethrough for running cables and such through the interior of the wall panel. The frame components may have angled ends, straight ends, or a combination thereof to collectively form a frame which may include corners. A wall system includes a plurality of such wall panels connected to one another along the outer surfaces of the frame components of their respective frames. Connectors and spacers may be inserted into the apertures as inserts and bridge between adjacent panels to selectively connect the panels. Caps may be placed in empty apertures to cover the openings for aesthetic purposes.

Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

Method for manufacturing on industrial scale of complete, highly reliable, flexible and accurate construction panels that are lightweight and have a very high R-value, wherein the processing is performed, under the control of a digital construction data file, by means of digitally controlled processing devices, such as milling and/or cutting devices. Portions of the construction panel from which the covering layer has been removed by the processing devices (such as the sides of recesses for door and window frames etcetera and optionally milled gutter slots) and portions of the construction panel of which the cover layer requires extra protection, such as portions below ground level, under control of the digital construction data file, are provided with a rigid and highly reliable protective layer of polyurea, polyester or epoxy by means of digitally controlled spraying devices. One or more delta robots can be used for mounting cladding elements such as a brick strip, which robots can be moved by means of the X-Y displacement system above the construction panel controllable from the digital construction data file.

Foam insulation boards having an improved shiplap edge for interfacing with one another are disclosed.

Light weight fiber-reinforced polymeric structural building panels and methods; sized, configured for fabrication of non-portable wall structures permanently fixed to natural base. The panel main body, and studs, can be fabricated separately, then assembled to each other to complete panel fabrication. Methods for making the main body are hand lay-up, or pultrusion. Studs are typically pultruded, and subsequently prepared having consistent thickness, flat surface, across the width of the stud end wall which is to be mounted to the main body. Foam blocks are between inner and outer layers of the panel. Foam blocks can be prepared in block clusters before assembly to the main body. In the main body, a fibrous layer is between each pair of next adjacent foam blocks. Intercostals extend “y” and “z” dimensions transverse to the length of the main body. Studs can be mounted to the main body using adhesive, mechanical fasteners, or both.

Foam wall structures and methods for making foam wall structures. The wall structures include a frame, a foam panel overlying a front surface of the frame, a first foam layer disposed in a cavity defined by the frame and the foam panel, in which the first foam layer self-adheres to one or more members of the frame, and a second foam layer disposed in the cavity. The second foam layer self-adheres to the first foam layer and has a density that is less than the density of the first foam layer.

A method of setting tile includes constructing a floor panel and a plurality of wall panels and attaching each of the plurality of wall panels to either the floor panel or one of the other wall panels with a waterproof caulk. Each of the wall panels includes a first rigid layer, a second rigid layer attached to the first rigid layer by a thinset mortar, and a waterproofing layer formed of a flexible material and attached to the second rigid layer by the thinset mortar.

A modular partition system comprises a plurality of panels and at least one connecting strip. Each of the plurality of panels comprises two support members extending generally perpendicularly to a plane of the modular partition system and a central panel extending between said two support panels. The plurality of panels are arranged such that the central panels of each of the plurality of panels are generally mutually parallel and one support member of each of the plurality of panels is adjacent to a support member of an adjacent panel. The at least one connecting strip cooperates with a support member from each of two of the plurality of adjacent panels so as to connect said two of the plurality of adjacent panels.

To attain an incombustible sound absorption panel by providing incombustibility to a sound absorption/insulation sandwich panel containing a combustible material as a constituting material.

Fine powder of chips generated during cutting of a foam material to fill in a honeycomb material is located in a gap between the foam material and a sound absorption surface material. A gap between fibers of the sound absorption surface material is blocked by the chips having been moved by a flow such as a water vapor flow generated from hydrate of the honeycomb material heated on the occurrence of a fire. As a result, an air flow path is limited. Further, carbon dioxide gas generated from the foam material is trapped to reduce an oxygen amount, thereby inhibiting combustion. Usage of an adhesive as a combustible material is reduced.

Described herein is a wall assembly for use in walls of energy efficient residential or commercial buildings which can provide improved thermal resistance, moisture resistance and structural capacity. The wall assembly includes a frame assembly; a laminated outer sheathing layer; and a closed cell inner foam layer for coupling the layer to the frame assembly. Also described herein is a method of manufacturing the wall assembly.