Construction panels

Abstract

A structural construction panel of the invention has an outer fiber-reinforced polymeric layer, and an inner fiber-reinforced polymeric layer. Thermally insulating foam generally occupies space which is not otherwise occupied between the inner and outer layers. A fire-rated capacity is provided by a fire-rated board, rated to pass at least a 15-minute corner fire test, incorporated as part of the finally-completed panel. Such fire-rated board can be foam-based, or non-foam-based. The fire-rated board product, whether a foam-based product or a non-foam-based product, can be enclosed in the panel between the inner and outer layers. Where the board is non-foam-based, the fire-rated board can be disposed, as part of the panel, as one or both outer surfaces of the panel structure, optionally between studs which protrude from the inner layer.

Description

BACKGROUND OF THE INVENTION[0001]This invention relates to building systems which use fiber reinforced polymeric. (FRP) construction panels to make structural walls and wall systems as primary support structures in buildings. Such reinforced construction panels largely replace concrete, for example ready-mix concrete, pre-fabricated concrete blocks, other pre-fabricated concrete products, or wood, or steel, or other conventional wall structure materials, in construction projects. In general, the invention replaces concrete in e.g. below-grade frost walls and foundation walls; can replace either concrete or wood or steel in above-grade walls. Thus, in the invention, structures based on resin-impregnated, fiber-based layers, as composite materials, also known as fiber-reinforced polymer materials (FRP) replace such conventional materials and structures. Structures of the invention typically include thermally insulating foam, and optionally include regularly-spaced “studs”, as part of ...

AI Technical Summary

Benefits of technology

[0008]This invention provides construction panels, and methods of making construction panels for a building system which provides wall, ceiling, and / or floor building panels and corresponding walls and wall sections, ceilings and ceiling sections, and floors and floor sections. The walls, taken in a vertical orientation, have both vertical compression-resistance strength, and horizontal bending-resistance strength, sufficient that the wall system can be used in below-ground building structural applications, as well as above-ground applications, including applications where such wall systems are exposed to severe wind and other weather, such as hurricanes, tornadoes, and the like as well as meeting all current United States of America fire-test requirements for panels devoid of any drywall covering. Construction panels of the invention, and corresponding walls, can replace concrete, meeting required strength specifications for use in single family residential, commercial, and industrial applications.

Problems solved by technology

Such furring takes up valuable interior space inside the building as well as adding to the cost, and time, needed for construction of the building.

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