Methods and systems for manufacturing foam wall structures
Methods for manufacturing foam wall structures are described. The methods include placing a wall structure proximate to a robotic arm, orienting an imaging device so that the imaging device on the robotic arm faces a cavity in the wall structure, surveying the cavity using the imaging device, determining a spray foaming pattern to fill the cavity to a selected depth with a foam layer, orienting the spray nozzle so the spray nozzle faces the cavity, and spray-applying the foam-forming composition into the cavity to the selected depth by passing the foam-forming composition through the spray nozzle to form the foam layer. Foam wall structure manufacturing systems that are suitable for carrying out such methods are also described.
1. A method for manufacturing a foam wall structure, comprising:
(a) conveying a wall structure with a conveyor so as to place the wall structure proximate to a robot comprising a robotic arm, the wall structure comprising:
(1) a frame comprising a first member, a second member that is spaced apart from the first member, and connecting members extending between the first member and the second member, wherein a front surface of the first member, a front surface of the second member, and a front surface of the connecting members form a front frame surface; and
(2) a panel attached to the front frame surface so that the panel, the first member, the second member, and the connecting members define an open cavity, wherein the robotic arm comprises:
(i) a spray nozzle, and
(ii) a camera;
(b) orienting the camera so that the camera faces the open cavity;
(c) surveying the open cavity using the camera to determine, using software code and based on an image produced by the camera, whether a foam layer is desired in the open cavity;
(d) if a foam layer is not desired in the open cavity, then repeating step (c) for another open cavity or, if a foam layer is desired in the open cavity, determining a spray foaming pattern to fill the open cavity to a selected depth with a foam layer;
(e) orienting the spray nozzle so that the spray nozzle faces the open cavity; and
(f) spray-applying a foam-forming composition into the open cavity according to the spray foaming pattern by passing the foam-forming composition through the spray nozzle to deposit the foam-forming composition in the open cavity to thereby form the foam layer.
2. The method of claim 1 , wherein the panel is a foam panel.
3. The method of claim 1 , wherein the wall structure is placed proximate to the robotic arm in a substantially horizontal orientation.
4. The method of claim 3 , wherein the robotic arm extends downwardly and is suspended over the conveyor when the spray nozzle is oriented to face the open cavity.
5. The method of claim 3 , wherein the robotic arm extends from a bridge comprising legs that are configured such that the wall structure is conveyed under the bridge between the legs of the bridge.
6. The method of claim 1 , wherein a computing device instructs the robot not to spray foam-forming composition into any open cavities of the wall structure containing a visual marking to indicate that no foam layer is desired.
7. The method of claim 1 , wherein a computing device receives data from the camera and determines, using software code, an amount of foam-forming composition components to add to achieve a required thickness for the foam layer and for determining a spray pattern to minimize variations in the depth of the foam layer.
8. The method of claim 7 , wherein the computing device retrieves quality data for the wall structure from a database, the quality data comprising a required average thickness of foam layer and/or a maximum deviation from a target thickness of the foam layer in any one location.
9. The method of claim 1 , wherein the foam layer comprises a polyurethane foam having a density of at least 2.8 lb/ft 3 (44.9 kg/m 3 ), when measured according to ASTM D1622-08.
10. The method of claim 1 , further comprising orienting the robotic arm so that the camera faces the open cavity of the wall structure in which a foam layer has been deposited and surveying the foam layer with the camera.
11. The method of claim 10 , further comprising re-orienting the robotic arm so the spray nozzle faces the open cavity and spray-applying the foam-forming composition into the open cavity to correct any deficiencies in the foam layer.
12. The method of claim 1 , wherein the conveyor is a belt conveyor, a roller conveyor, a slat conveyor, a chain conveyor, a hand push beam trolley system, or a monorail.
13. A method for manufacturing a foam wall structure, comprising:
(a) conveying a wall structure with a conveyor so as to place the wall structure proximate to a robot comprising a robotic arm, the wall structure comprising:
(1) a frame comprising a first member, a second member that is spaced apart from the first member, and connecting members extending between the first member and the second member, wherein a front surface of the first member, a front surface of the second member, and a front surface of the connecting members form a front frame surface; and
(2) a panel attached to the front frame surface so that the panel, the first member, the second member, and the connecting members define an open cavity, wherein the robotic arm comprises:
(i) a spray nozzle, and
(ii) a camera;
(b) orienting the camera so that the camera faces the open cavity;
(c) surveying the open cavity using the camera to determine, using software code and based on an image produced by the camera, whether a foam layer is desired in the open cavity;
(d) if a foam layer is not desired in the open cavity, then repeating step (c) for another open cavity or, if a foam layer is desired in the open cavity, determining a spray foaming pattern to fill the open cavity to a selected depth with a foam layer;
(e) orienting the spray nozzle so the spray nozzle faces the open cavity;
(f) spray-applying a foam-forming composition into the open cavity according to the spray foaming pattern by passing the foam-forming composition through the spray nozzle to form the foam layer;
(g) orienting the camera so that the camera faces the open cavity of the wall structure in which the foam layer has been deposited; and
(h) surveying the foam layer using the camera.
14. The method of claim 13 , further comprising orienting the spray nozzle so the spray nozzle faces the foam layer and spray-applying the foam-forming composition into the open cavity to correct any deficiencies in the foam layer.
15. The method of claim 13 , wherein the panel is a foam panel.
16. The method of claim 13 , wherein the wall structure is placed proximate to the robotic arm in a substantially horizontal orientation.
17. The method of claim 16 , wherein the robotic arm extends downwardly and is suspended over the conveyor when the spray nozzle is oriented to face the open cavity.
18. The method of claim 16 , wherein the robotic arm extends from a bridge comprising legs that are configured such that the wall structure is conveyed under the bridge between the legs of the bridge.
19. The method of claim 13 , wherein a computing device instructs the robot not to spray foam-forming composition into any cavities of the wall structure containing a visual marking to indicate that no foam layer is desired.
20. The method of claim 13 , wherein a computing device receives data from the camera and determines, using software code, an amount of foam-forming composition components to add to achieve a require thickness for the foam layer and for determining a spray pattern to minimize variations in the depth of the foam layer, wherein the determination comprises retrieving quality data for the wall structure from a database, the quality data comprising a required average thickness of foam layer and/or a maximum deviation from a target thickness of the foam layer in any one location.
21. The method of claim 13 , wherein the foam layer comprises a polyurethane foam having a density of at least 2.8 lb/ft 3 (44.9 kg/m 3 ), when measured according to ASTM D1622-08.
22. The method of claim 13 , wherein the conveyor is a belt conveyor, a roller conveyor, a slat conveyor, a chain conveyor, a hand push beam trolley system, or a monorail.