Reinforced heat-insulating structure panel

Abstract

A reinforced structural panel and a method for manufacturing the reinforced structural panel are described herein. The reinforced structural panel has a heat insulation layer (130), an outer layer (120) adjacent to a first lateral surface of the heat insulation layer, and a plurality of reinforcing structures (122, 124, 126, 128) fixed between the heat insulation layer and the outer layer. The reinforcing structures can be a cementitious material such as wood or magnesium oxide. The outer layer of the reinforced structural panel can be any wood board or a cement board such as magnesium oxide or gypsum. The plurality of reinforcing structures can extend parallel to the length or width of the structural panel. The plurality of reinforcing structures can be at least partially attached to the outer layer with an adhesive.

Description

Technical Field

[0001] The present disclosure generally relates to reinforced structural panels for use in the field of building structures and building structural materials.

Background Art

[0002] Structural insulated sheathing (SIS) panels can be used in standard building practices. Such panels typically consist of a thermal insulation core and one or more structural layers. The structural layers can be wood or wood composite materials such as oriented strand board (OSB) boards or plywood; cementitious materials such as magnesium oxide or gypsum; steel; aluminum; and fiber reinforced plastics. The use of SIS panels offers many advantages over conventional buildings consisting of frameworks and scaffolds. Since such panels are made off-site, assembly is very fast, labor costs are significantly reduced, and by using them in walls, roofs, or structures, an energy-efficient structure is provided.

[0003] Finishing materials such as siding and roofing sheets are generally fixed to the SIS via fasteners, and it is desirable for the fasteners to properly fix the finishing materials to the SIS. In particular, it is desirable for the SIS to help prevent the withdrawal of the fasteners in the final wall or structure and for the SIS to have improved mechanical integrity. By improving the fastener withdrawal characteristics and shear values of the SIS, the performance of the SIS is improved, and it is considered possible to use it in new applications, for example, in strong wind zones, heavy finishing materials, or roof attachments.

[0004] Metal strip reinforcements may be used in the panels, but metals can corrode due to damage to the boards during construction and water ingress into the boards due to poor sealing of the board openings, and there is also a possibility of other chemical corrosion.

[0005] Accordingly, what is needed is a panel that, when used in combination with a finish material, provides improved fastener withdrawal characteristics and mechanical integrity without the risk of corrosion, particularly a thermal insulation panel suitable for use as a structural insulating sealant (SIS). SUMMARY OF THE INVENTION MEANS FOR SOLVING THE PROBLEM

[0006] Reinforced structural panels and methods of manufacturing the reinforced structural panels are disclosed that are consistent with and harmonize with the present disclosure.

[0007] In one aspect, a reinforced structural panel is claimed. A reinforced structural panel having a thermal insulation layer, an outer layer adjacent to a first lateral surface of the thermal insulation layer, and a plurality of reinforcing structures within the reinforced structural panel. The plurality of reinforcing structures are fixed between the thermal insulation layer and the outer layer. The reinforcing structure can be wood or a cementitious material.

[0008] In some embodiments, the reinforced structural panel can further include an additional outer layer on a lateral surface opposite the thermal insulation layer. In further embodiments, the additional outer layer can include an additional plurality of reinforcing structures fixed between the thermal insulation layer and the additional outer layer.

[0009] In some embodiments, each of the reinforcing structures can have a length equal to that of the outer layer. Additionally or alternatively, each of the reinforcing structures can have a width of 1 inch or more and 12 inches or less. In some embodiments, each of the reinforcing structures can have a width of 2 inches or more and 5 inches or less. In some embodiments, each of the reinforcing structures can have a width of 2 inches or more and 3 inches or less. In some embodiments, the depth of each of the reinforcing structures is 0.25 inches or more and 1.5 inches or less. Additionally or alternatively, each of the reinforcing structures has a density equal to the density of the outer layer. In some embodiments, each of the reinforcing structures has a density greater than the density of the outer layer.

[0010] In some embodiments, the outer surface of the outer layer may include markings indicating the respective positions of the reinforcing structures. Additionally or alternatively, the outer surface of the outer layer may include a water-resistant barrier. In some embodiments, the outer layer includes magnesium oxide. In some embodiments, the outer layer includes gypsum. Additionally or alternatively, the outer layer includes a cement board. In some embodiments, each of the outer layer and the reinforcing structure includes magnesium oxide. In some embodiments, the thermal insulation layer includes polyurethane.

[0011] In another aspect, a method of manufacturing a reinforced structural panel is claimed. The method of manufacturing a reinforced structural panel includes adhering a plurality of reinforcing structures composed of wood or cementitious materials to the surface of a board, and applying a thermal insulation layer to the plurality of reinforcing structures and the surface of the board. In some embodiments, the board can be wood, gypsum, magnesium oxide, or cement. In some embodiments, the method further includes forming the reinforcing structures.

[0012] In some embodiments, the method further includes applying a second board to the thermal insulation layer. In further embodiments, the second board can first be adhered to the plurality of reinforcing structures. In some embodiments, the method further includes applying a water-resistant barrier to the outer-facing surface of the board.

[0013] In another aspect, a method of forming a reinforcing structure is claimed. The method of forming a reinforcing structure includes obtaining a panel of wood or cementitious material, and cutting strips of the same length as the panel from the panel. In some embodiments, the strips are 1 to 12 inches in width. Additionally or alternatively, the strips can be 2 to 4 inches in width.

[0014] In some embodiments, the method of forming the reinforcing structure further includes forming a panel. Forming the panel includes pouring a slurry of an uncured cementitious product into a mold and curing the cementitious product. In some embodiments, the slurry of the uncured cementitious product includes magnesium oxide and glass fibers. In some embodiments, the method of forming the reinforcing structure includes applying an adhesive to a strip.

[0015] In another aspect, a reinforced structural panel is claimed. A reinforced structural panel having a thermal insulation layer, an outer layer including magnesium oxide adjacent to a first lateral surface of the thermal insulation layer, and a plurality of reinforcing structures composed of magnesium oxide within the reinforced structural panel. The plurality of reinforcing structures are fixed between the thermal insulation layer and the outer layer.

[0016] In another aspect, a reinforced structural panel is claimed. A reinforced structural panel having a thermal insulation layer, an outer layer including gypsum adjacent to a first lateral surface of the thermal insulation layer, and a plurality of reinforcing structures composed of magnesium oxide within the reinforced structural panel. The plurality of reinforcing structures are fixed between the thermal insulation layer and the outer layer.

[0017] In another aspect, a reinforced structural panel is claimed. A reinforced structural panel having a thermal insulation layer, an outer layer including wood adjacent to a first lateral surface of the thermal insulation layer, and a plurality of reinforcing structures composed of magnesium oxide within the reinforced structural panel. The plurality of reinforcing structures are fixed between the thermal insulation layer and the outer layer.

[0018] In another aspect, a reinforced structural panel is claimed. A reinforced structural panel having a thermal insulation layer, an outer layer including cement board adjacent to a first lateral surface of the thermal insulation layer, and a plurality of reinforcing structures composed of magnesium oxide within the reinforced structural panel. The plurality of reinforcing structures are fixed between the thermal insulation layer and the outer layer.

[0019] The drawings described in this specification are for the purpose of illustrating examples of selected embodiments and are not intended to be all possible embodiments or to limit the scope of the disclosure.

Brief Description of the Drawings

[0020]

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Modes for Carrying Out the Invention

[0021] The following detailed description and the accompanying drawings describe and illustrate various embodiments of the present invention. This description and the drawings are provided to enable those skilled in the art to make and use the present invention and are not intended to limit the scope of the present invention in any way. With respect to the disclosed methods, the steps presented are exemplary in nature, and thus the order of the steps is neither necessary nor critical.

[0022] It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0023] Terms such as "first", "second", "third", etc. may be used herein to describe various elements, components, regions, layers, and / or sections, but these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another. Terms such as "first", "second", etc. and other numerical terms, when used herein, do not imply order or sequence unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below may be referred to as a second element, component, region, layer, or section without departing from the teachings of this exemplary embodiment.

[0024] Spatially relative terms, such as "inner", "outer", "beneath", "below", "lower", "above", "upper", etc., may be used herein for ease of description to describe the relationship of one element or feature to another as illustrated. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation shown in the figures. For example, if the device in the figures is turned over, an element described as "below" or "beneath" another element or feature will then be oriented "above" the other element or feature. Thus, the exemplary term "below" can encompass both an upward and a downward orientation. The device may be oriented in other ways (rotated 90 degrees or at other orientations), and the spatially relative descriptors used herein are to be interpreted accordingly.

[0025] The reinforcement within the panel is designed to improve the strength and mechanical integrity of the outer layer and thus the overall SIS. The reinforcement measures within the panel utilize engineering designs generally recognized for attachment loads of finish materials in higher wind zones equivalent to structural surfaces while maintaining higher thermal efficiency because the insulation is truly continuous as defined by IECC (International Energy Conservation Code) for materials that do not interrupt except at mechanical openings and fasteners. The fasteners used to attach the seaming to the studs are likely to be installed by the reinforcement measures, so the outer reinforcement measures become the structural surface and maintain a thermal efficiency of over 97%.

[0026] For the manufacturing process of a composite panel having an adhesively and / or fusion-bonded insulation material, prior to attaching the insulation material, it is possible to place a structural reinforcement strip with a width of 1 inch to 12 inches composed of magnesium oxide or wood behind the seaming surface of gypsum, wood, or magnesium oxide. The insulation material is then fixed to the structural reinforcement strip against or within 0.25 inches of the surface of the outer layer.

[0027] This reinforcement strip combined with the outer layer serves to distribute the point load of the finish material fastener as a distributed load over the wall panel. This load distribution allows the pull-out force of the finish material fastener to increase non-linearly more than in the conventional methodology for a single sheet panel alone and, in many cases, to increase the shear value and pull-out value to more than twice the single sheet value.

[0028] The wall panels described herein are reinforced structural panels used as Structural Insulated Sheathing (SIS) or Structural Insulated Panels (SIP). Referring to FIG. 1, the reinforced structural panel may include a thermal insulation layer 130, an outer layer 120, and a plurality of reinforcing structures 122, 124, 126, and 128 on the inner surface of the outer layer 120. As shown in the cross-sectional view of FIG. 2, the reinforcing structure is surrounded or embedded in the thermal insulation layer 130 on the surface of the outer layer 120. The outer layer may include magnesium oxide, gypsum, wood, or other cementitious materials. As used herein, "magnesium oxide" means including magnesium oxychloride, or magnesiumoxysulfate, or magnesium oxyphosphate, or combinations thereof, and may include fillers (such as perlite) and other additives such as water resistance and processing additives.

[0029] The reinforcing structure is a thin strip of wood or cementitious material attached to the inner surface of the outer layer 120. The panel surface may have surfaces with large and small dimensions. In some preferred embodiments, the reinforcing structure is parallel to the large panel dimension, as shown by the reinforced structural panel 100 of FIG. 1. In some embodiments, the reinforcing structure is parallel to the small panel dimension, as shown by the reinforced structural panel 200 of FIG. 6. Additionally or alternatively, the reinforcing structure is the same length as the large panel dimension. In some other embodiments, the reinforcing structure is the same length as the small panel dimension of the panel. In some embodiments, the reinforcing structures are spaced equidistantly along the width of the inner surface of the outer layer. In some embodiments, the reinforcing structures are spaced equidistantly along the length of the inner surface of the outer layer.

[0030] In an example where the panel is 4 feet wide, there are four reinforcement structures evenly spaced every 16 inches. In this example, the edge of the first reinforcement structure is located at the edge of the panel, and the center of the second reinforcement structure is fixed at a distance of 16 inches from the edge of the panel. The center of the third reinforcement structure is fixed at a distance of 16 inches from the center of the second reinforcement structure, and the edge of the fourth reinforcement structure is located at the second edge of the panel, which is 16 inches from the center of the third reinforcement structure. Although a 4-foot-wide panel is described in the above example, the present invention is not limited to the described exemplary dimensions.

[0031] In some embodiments, the reinforced structural panel may include an additional outer layer 140, as shown in the cross-sectional view of FIG. 3. The embodiment shown in FIG. 3 includes a second outer layer 140 on the opposite side of the outer layer 120. In some embodiments, the additional outer layer 140 may further include a reinforcement structure, as shown in the cross-sectional view of FIG. 4. The additional outer layer 140 may have additional reinforcement structures 142, 144, 146, and 148. In some embodiments, the reinforcement structure is positioned at the edge of the panel, as shown in the cross-sectional views of FIGS. 2-4. Additionally or alternatively, the reinforcement structure is not positioned at the edge of the panel, as shown in the cross-sectional view of FIG. 5.

[0032] The reinforcement structure may be composed of wood or a cement-based material. The use of a cement-based material such as magnesium oxide as the reinforcement structure provides a fire-resistant reinforcement structure. When combined with a fire-resistant outer layer such as an outer layer composed of magnesium oxide, the reinforced structural panel is completely fire-resistant.

[0033] The reinforced structural panel may also be configured to be water-resistant. In some embodiments, the reinforced structural panel may further include a water-resistant barrier (WRB). The WRB may be applied to the outward-facing surface of the outer layer of the reinforced structural panel.

[0034] The reinforced structural panel described in this specification can be manufactured by adhering a plurality of reinforcing structures onto a first surface of a board. The board functions as an outer layer of the reinforced structural panel. In some embodiments, the reinforcing structures may be adhered at regular intervals and may be equally spaced across the width of the board. In some embodiments, the reinforcing structures may be from 1 inch to 12 inches in width. Additionally or alternatively, the reinforcing structures may be from 1 inch to 10 inches in width. In some embodiments, the reinforcing structures may be from 1 inch to 8 inches in width. Additionally or alternatively, the reinforcing structures may be from 1 inch to 6 inches in width. In some embodiments, the reinforcing structures are from 1 inch to 4 inches in width. Additionally or alternatively, the reinforcing structures are from 2 inches to 4 inches in width. In some embodiments, the reinforcing structures have the same length as the board.

[0035] The board or outer layer forming the outer layer may include magnesium oxide, gypsum, wood, or a cementitious material. "Cementitious material" means a material containing magnesium oxide as defined herein, or other cement types such as Portland cement; or any mixture of these materials. "Wood" as used herein is understood to include oriented strand board (OSB) or other composite materials containing wood products or wood by-products or plywood. The board or outer layer forming the outer layer may contain magnesium oxide. In some embodiments, the board or outer layer forming the outer layer may further include gypsum. Additionally or alternatively, the board or outer layer forming the outer layer may entirely include gypsum.

[0036] In some embodiments, the outer layer can be a board made of a cementitious material having glass fiber reinforcement material embedded therein. Additionally or alternatively, the board can be formed by pouring a slurry of a cementitious material containing glass fiber reinforcement material into a mold and curing or drying the cementitious product. The glass fiber reinforcement material can be in the form of chopped glass fibers. Additionally or alternatively, the glass fiber reinforcement material can be incorporated into the board in the form of one or more glass fiber scrims. After curing, the board can be removed from the mold before adhering the reinforcement structure to the inner surface of the board.

[0037] After adhering the reinforcement structure to the board, a thermal insulation layer is applied over the reinforcement structure and the first surface or inner surface of the board. The thermal insulation layer functions as a primary mechanism for holding the reinforcement structure in place. In some embodiments, the thermal insulation layer is injected at high pressure, and thus the use of an adhesive for applying strips to the board may be required to prevent the reinforcement structure from coming loose and "floating" during application of the thermal insulation layer.

[0038] The heat insulation layer may be 1 inch to 3 inches or more in thickness, depending on the application. In some embodiments, the heat insulation layer is 2 inches thick. In some embodiments, the heat insulation layer includes polyurethane or polyester. In some embodiments, the heat insulation layer may include polystyrene. Examples of polystyrene heat insulation materials include expanded polystyrene foam and extruded polystyrene foam. Additionally or alternatively, the heat insulation layer may include polyisocyanurate, polyurea, phenolic foam, or organic aerogel. In some embodiments, the heat insulation layer may include an inorganic heat insulation material, such as mineral wool, glass wool, compressed fumed silica, perlite, calcium silicate, foam glass, or silica aerogel blanket. In some embodiments, the heat insulation layer may be a machined pre-made foam that surrounds the reinforcing structure and includes slots sized to fit onto the outer layer. In some embodiments, the heat insulation layer may include mineral wool. In some embodiments, the heat insulation layer may be a rigid poured foam or may be injection molded from a two-component Class I urethane.

[0039] In some embodiments where the reinforced structural panel includes a second outer layer, a second board may be applied. In some embodiments, the second board is applied after the application of the heat insulation layer. In some embodiments, the second board is applied before the application of the heat insulation layer, and the heat insulation layer is applied between the two boards. In some embodiments, before applying the second board, a plurality of additional reinforcing structures are adhered to the second board in the manner described above.

[0040] The reinforcing structure can be formed by obtaining a panel of wood or a cementitious material. In some embodiments, the panel can be the same board as the outer layer of the reinforced structural panel. In other embodiments, the panel may be different from the board of the outer layer of the reinforced structural panel. After obtaining the panel, the method continues by cutting strips from the panel. The strip may be the same length as either the major surface dimension or the minor surface dimension of the panel, as described previously herein. The strip can have a width of from 1 inch to 12 inches. In some embodiments, the strip can have a width of from 1 inch to 10 inches. In some embodiments, the strip can have a width of from 1 inch to 8 inches. In some embodiments, the strip can have a width of from 1 inch to 6 inches. In some embodiments, the strip can have a width of from 1 inch to 4 inches. Additionally or alternatively, the strip can have a width of from 2 inches to 5 inches. Additionally or alternatively, the strip can have a width of from 2 inches to 3 inches. The depth of the reinforcing structure is determined by the panel from which the strip is cut. In some embodiments, the reinforcing structure has a depth of from about 0.25 inches to about 1.5 inches. Additionally or alternatively, the reinforcing structure has a depth of about 0.5 inches.

[0041] In some embodiments, when the reinforcing strip includes a cementitious material, the panel is cut from a composite cementitious panel. In some embodiments, the composite cementitious panel can be made from a slurry of an uncured cementitious material such as magnesium oxide, in which a glass fiber reinforcing material is embedded. The slurry can be poured into a mold and can be cured or dried. After curing, the panel can be removed from the mold. The composite cementitious panel can have a thickness of from about 0.25 inches to about 1.5 inches. In some embodiments, the composite cementitious panel has a thickness of about 0.5 inches.

[0042] In some embodiments, when a reinforced structural panel that is water resistant is desired, a water resistant barrier (WRB) may be applied to the outer surface of the outer layer. The WRB can be any commercially available WRB known in the art. In some embodiments, the WRB can be a liquid applied to the surface by spraying, painting, or coating. Additionally or alternatively, the WRB can be a sheet adhered to the surface.

[0043] When the WRB is in the form of a sheet, a preferred WRB sheet meets the requirements of building standards such as ASTM E2556, the standard specification for WRB. This standard requires a dry tensile strength (both machine direction and cross direction (MD / CD)) according to ASTM D828 of at least 20 pounds per inch of force, and water resistance according to AATCC 127 (held at 55 cm) with no leakage in 5 hours. A useful WRB sheet is generally any sheet material that does not allow or limits the movement of liquid water through the sheet, but allows some movement of vapor, particularly water vapor, through the sheet. In some embodiments, the WRB sheet is polymeric. Preferred polymeric sheets are polyethylene (PE) or polypropylene (PP). One preferred WRB sheet is a non-woven fiber web of flash-spun plexifilament-like high-density PE (HDPE) fibers sold under the trade names Tyvek® Homewrap® or Tyvek® CommercialWrap from DuPont, Wilmington, DE. Suitable polypropylene substrates are available under the trade name Typar® Building Wraps. Alternatively, when the WRB is a coating on the outer layer, the coating is preferably a polymeric coating having a vapor permeability superior to that of the insulation layer when measured according to ASTM E96 / E96M-22. Preferably, the coating comprises a polymer made from any of acrylate monomers, styrene monomers, or some combination thereof.

[0044] Although the materials and methods of the present disclosure have been described with reference to several embodiments, those skilled in the art will understand that the invention is not limited to the disclosed embodiments. Rather, the invention may be modified to incorporate any number of variations, modifications, and alterations that are not described herein but are commensurate with the scope of the invention.

Examples

[0045] To demonstrate the improvement of the pull-out performance of the fastener of the structure including the reinforcing structure, a reinforced board was fabricated and tested in accordance with ASTM D1761-20, Standard Test Methods for Mechanical Fasteners in Wood. The variation from the method was the crosshead speed, which was 0.5 inches per minute. Concealor® #10-9x 1-5 / 8 inch screw fasteners were obtained from the manufacturer and tested as received. A 4.5-inch-wide strip-shaped reinforcing structure was cut out from one 4-foot × 8-foot board made of magnesium oxide board embedded with a glass fiber scrim. Next, using this strip, a structural insulating sealing (SIS) was fabricated that included an outer layer of a board made of magnesium oxide board embedded with a glass fiber scrim, a strip spaced adjacent to the outer layer, and a foam for holding the strip in place. The final thickness of the SIS was 2.75 inches. To show the improved performance, the fastener was screwed into the outer board, into the adjacent strip, and penetrated. As a control, the fastener was screwed only into the outer board and the foam so as not to hit the reinforcing strip. The screw was not screwed in to be flush with the surface of the outer layer, but was screwed in to a depth where a part of the fastener was exposed outside the outer layer so that the test fixture could grip the fastener. Then, using a Shimadzu AGS-X 10kN universal testing machine (part number 337-01261-21), a 10,000 Newton load cell (model SSM-DAL-10KN) was actuated, and the fastener was removed from the SIS at a crosshead speed of 0.5 inches per minute. All conditioning and test conditions of the test specimens were set as standard laboratory conditions of 72°F ± 5.0°F and relative humidity of 50% ± 10%.

[0046] In some cases, the addition of foam placed on the outer layer of the magnesium oxide board and the reinforcing structure (strip) was found to actually push the strip away from contact with the board in some areas as the foam expanded during the production of the SIS.

[0047] The force (pull-out force) required to remove the fastener that is screwed into the outer board and also screwed into the adjacent strip fixed by the heat insulating material in surface contact with the outer board and passes through the adjacent strip was found to increase by 139 percent when compared to the force required to remove the fastener that is only screwed into the outer board and the foam. Also, the force required to remove the fastener that is screwed into the outer board and also screwed into the adjacent strip fixed by the heat insulating material in surface contact with the outer board and passes through the adjacent strip was found to increase by 185 percent when compared to the force required to remove the fastener that is only screwed into the outer board. The improvement in the pull-out performance of these fasteners was unexpected. This is because while the amount of board material doubles (a 100% increase) by using the reinforcing structure, the actual performance was much higher. Furthermore, this performance was obtained with little additional weight added to the SIS.

[0048] A further unexpected result is that the force (pull-out force) required to remove the fastener that is screwed into the outer board, also screwed into the adjacent strip, and passes through the adjacent strip was found to exhibit unexpected fastener pull-out performance in a state where, although the strip was pushed 0.25 inches away from surface contact with the board in some areas as the foam expanded during the production of the SIS, it was further fixed in place by the heat insulating material. When compared to the force required to remove the fastener that is only screwed into the outer board and the foam, the pull-out force of these fasteners increased by as much as 123 percent, and further, when compared to the force required to remove the fastener that is only screwed into the outer board, the pull-out force increased by as much as 166 percent.

Claims

1. A reinforced structural panel, comprising: a heat-insulating layer; an outer layer adjacent to a first lateral surface of the heat-insulating layer; and a plurality of reinforcing structures within the reinforced structural panel, the plurality of reinforcing structures being fixed between the heat-insulating layer and an inner surface of the outer layer and including wood or a cement-based material. A reinforced structural panel comprising the above.

2. The reinforced structural panel according to claim 1, further comprising a second outer layer adjacent to a second lateral surface of the heat-insulating layer.

3. The reinforced structural panel according to claim 2, further comprising a second plurality of reinforcing structures within the reinforced structural panel, the second plurality of reinforcing structures being fixed between the heat-insulating layer and an inner surface of the second outer layer and including wood or a cement-based material.

4. The reinforced structural panel according to claim 1, wherein each of the plurality of reinforcing structures includes a length, and the length of each reinforcing structure is equal to either the length or the width of the outer layer.

5. The reinforced structural panel according to any one of claims 1 to 5, wherein each of the plurality of reinforcing structures includes a width, and the width of each reinforcing structure is from 1 inch to 12 inches.

6. The reinforced structural panel according to claim 5, wherein the width of each reinforcing structure is from 2 inches to 5 inches.

7. The reinforced structural panel according to claim 6, wherein the width of each reinforcing structure is from 2 inches to 3 inches.

8. The reinforced structural panel according to any one of claims 1 to 7, wherein each of the plurality of reinforcing structures includes a depth, and the depth is from 0.25 inch to 1.5 inches.

9. The reinforced structural panel according to any one of claims 1 to 8, wherein each of the plurality of reinforcing structures has a density higher than the density of the outer layer.

10. The reinforced structural panel according to any one of claims 1 to 8, wherein each of the plurality of reinforcing structures has a density equal to the density of the outer layer.

11. The reinforced structural panel according to any one of claims 1 to 10, further comprising markings on an outer surface of the outer layer indicating positions of each of the plurality of reinforcing structures.

12. The reinforced structural panel according to any one of claims 1 to 11, wherein the outer layer includes magnesium oxide.

13. The reinforced structural panel according to any one of claims 1 to 11, wherein the outer layer contains gypsum.

14. The reinforced structural panel according to any one of claims 1 to 11, wherein the outer layer contains wood.

15. The reinforced structural panel according to any one of claims 1 to 11, wherein the outer layer contains a cement-based material.

16. The reinforced structural panel according to any one of claims 1 to 15, further comprising a water-resistant barrier on the outer surface of the outer layer.

17. The reinforced structural panel according to any one of claims 1 to 16, wherein both the outer layer and the plurality of reinforcing structures contain magnesium oxide.

18. The reinforced structural panel according to any one of claims 1 to 17, wherein the heat-insulating layer contains polyurethane or polyester.

19. A method for manufacturing a reinforced structural panel, placing a plurality of reinforcing structures on a first surface of a board, wherein the plurality of reinforcing structures contain wood or a cement-based material; applying a heat-insulating layer to the plurality of reinforcing structures and the first surface of the board; and a method including this.

20. The method for manufacturing a reinforced structural panel according to claim 19, further comprising applying a second board to the heat-insulating layer.

21. The method for manufacturing a reinforced structural panel according to claim 20, further comprising adhering a plurality of reinforcing structures to an inward-facing surface of the second board before applying the second board.

22. The method for manufacturing a reinforced structural panel according to claim 19, further comprising applying a water-resistant barrier to an outward-facing surface of the board.

23. The method for manufacturing a reinforced structural panel according to claim 19, wherein the board contains wood, gypsum, magnesium oxide or a cement-based material.

24. The method further includes forming a reinforcing structure, and forming the reinforcing structure includes: obtaining a panel, wherein the panel contains wood or a cement-based material; cutting a strip from the panel, wherein the strip has the same length as the panel and the strip has a width greater than 1 inch and less than 12 inches; and a method for manufacturing a reinforced structural panel according to claim 19 including this.

25. Forming the reinforcing structure further includes forming the panel, and forming the panel includes pouring a slurry of an uncured cementitious material into a mold, and curing the slurry of the uncured cementitious material, The method for manufacturing a reinforced structural panel according to claim 24, comprising:

26. The method for manufacturing a reinforced structural panel according to claim 25, wherein the slurry of the uncured cementitious material contains magnesium oxide and glass fibers.

27. Applying a heat insulation layer to the first surface of the plurality of reinforcing structures and the board includes injecting a two-component urethane foam onto the first surface of the plurality of reinforcing structures and the board. The method for manufacturing a reinforced structural panel according to claim 19.

28. The method for manufacturing a reinforcing structure according to claim 19, further comprising applying an adhesive to the reinforcing structure before disposing the reinforcing structure on the first surface of the board.

29. A reinforced structural panel, comprising: a heat insulation layer; an outer layer adjacent to the first lateral surface of the heat insulation layer, the outer layer containing magnesium oxide; a plurality of reinforcing structures within the reinforced structural panel, the plurality of reinforcing structures being fixed between the heat insulation layer and the inner surface of the outer layer and containing magnesium oxide; A reinforced structural panel comprising:

30. A reinforced structural panel, comprising: a heat insulation layer; an outer layer adjacent to the first lateral surface of the heat insulation layer, the outer layer containing gypsum; a plurality of reinforcing structures within the reinforced structural panel, the plurality of reinforcing structures being fixed between the heat insulation layer and the inner surface of the outer layer and containing magnesium oxide; A reinforced structural panel comprising:

31. A reinforced structural panel, comprising: a heat insulation layer; an outer layer adjacent to the first lateral surface of the heat insulation layer, the outer layer containing wood; a plurality of reinforcing structures within the reinforced structural panel, the plurality of reinforcing structures being fixed between the heat insulation layer and the inner surface of the outer layer and containing magnesium oxide; A reinforced structural panel comprising:

32. A reinforced structural panel, comprising: a heat insulation layer; an outer layer adjacent to the first lateral surface of the heat insulation layer, the outer layer including a board containing a cementitious material; a plurality of reinforcing structures within the reinforced structural panel, the plurality of reinforcing structures being fixed between the heat insulation layer and the inner surface of the outer layer and containing magnesium oxide; A reinforced structural panel comprising:

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