BRPI0720187A2 - CONSTRUCTION PANELS AND CONSTRUCTION SYSTEMS AND METHODS - Google Patents

Description

CONSTRUCTION PANELS AND CONSTRUCTION SYSTEMS AND METHODS BACKGROUND OF THE INVENTION

This invention relates to building systems that vastly replace concrete, whether ready-mix concrete or prefabricated concrete blocks, or other prefabricated concrete products, in construction projects. In general, the invention replaces concrete in below-average opaque walls and foundation walls, above-average walls, in concrete bases, and in column wedges. Such concrete structures are replaced in the invention by resin-impregnated fiber-based layer-based structures such as composite materials, also known as fiber reinforced polymer (FRP) materials. Such structures optionally include insulating foam, and optionally include regularly spaced "pins", especially on vertical wall sections. Therefore, with the exception of flat concrete work such as concrete floors, the conventional ready mix concrete truck is not required at the construction site.

In conventional foundation construction, a concrete base is first formed and poured using ready mix concrete. After the poured concrete base has cured to a sufficient degree, such as a few days later, concrete formwork, for example 1.22-2.44 m in height, is brought, assembled on site, and erected at the top. from the base. The ready mix concrete is then poured from a ready mix truck into the forms and allowed to settle and cure to thereby create the foundation walls, or an opaque wall if no foundation is planned. Alternatively, while still addressing the conventional foundation construction, the vertical portion of the foundation wall may be laid using prefabricated concrete masonry units (cmu's) and mortar, usually supported by conventional poured concrete bases.

In yet another construction of the conventional type, opaque walls or foundation walls are constructed using concrete blocks.

In any event, in such conventional structures, as concrete is being finalized in the upper part of the formwork, or in the upper path of concrete blocks, bolts or other safety anchors are partially incorporated into the concrete laying or mortar so that the anchors extend from the top of the foundation wall, and once the poured concrete or mortar has formed, such anchors act as safety anchors, for example to mount an upper plate to the top of the foundation wall , to thereby anchor the building structure overlying the opaque foundation or wall. Once the concrete in a conventionally poured wall settles, the formwork is removed, for example 1-2 days after the ready mix concrete is poured into the formwork, and a wood, or wood product, or other top plate is anchored to the top of the concrete foundation wall using the anchors that are embedded in the concrete at the top of the concrete foundation wall. Similar waiting time is required with a mortar concrete block wall before the top plate is anchored to the top of the wall thus manufactured.

The poured concrete wall construction process noted above, and the concrete block construction process, both require a substantial amount of concrete materials, investment in formwork, substantial on-site work and several days of time to fabricate the foundation. building in which the ground floor of the building can then be erected. If built in the winter in a Nordic climate, the concrete is usually heated to facilitate curing of the concrete.

In addition, such a resulting concrete foundation wall is water permeable and therefore must be made waterproof however, even after a conventional waterproof coating has been applied to make the foundation wall waterproof. water, leaking water through such a concrete foundation wall, be it ready mix wall or concrete block wall, is more common. In addition, a concrete wall is a good conductor of heat, and thus should be insulated to prevent heat loss by conducting through the concrete to the ground or other embankment surrounding the building. However, the effect of such insulation is limited because only relatively thin insulation materials are commonly used with underground concrete wall construction.

Still further, if the interior level of construction of the concrete wall is to be vacated, either below average, eg foundation wall, or above average, then pin liner, for example 2x4 pins or 2x6 pins They are usually attached to the concrete wall as a substrate that facilitates the installation of insulation and utilities, and functions as a substrate for installing a finished interior wall surface such as laminated rock or paneling. Such lining takes up interior space within the building as well as costs additional time and money to install.

The overall time required to build such a building foundation can be reduced by fabricating off-site concrete walls and lifting in-place fabricated walls using a crane. However, each such wall element must be custom designed, adding to the cost; and mechanical lifting equipment, for example the crane, must be brought to the construction site.

Installing foundation walls in a timely manner to accommodate timely delivery of built residences and other buildings to buyers is a significant issue in the construction business. There are many reasons why foundations are not installed according to a planned schedule. One such substantial problem is the weather. The weather in Nordic climates can be below freezing for many months of the year, which makes it difficult to have foundations installed. In addition, installing quality concrete foundation walls requires skilled work as well as skilled subcontractors, including skilled work of subcontractors.

Another known method for building structural walls is the use of Insulated Concrete Formwork (ICF) walls. In such a construction, insulated forms are erected at the bases, and receive ready-poured concrete. After curing, the outer portions of the formwork are left as a thermal insulation layer between the concrete and at least one of the inner and outer surfaces of the resulting wall. Although ICF walls offer a relatively higher level of thermal insulation than a conventional uninsulated concrete wall, an ICF wall is usually more expensive than a simple concrete wall, and is harder to finish than a simple concrete wall. , either finishing the insulated wall interior or the insulated wall exterior.

Yet another alternative conventional foundation wall system is constructed of wood that has been treated to inhibit decay, and corresponding decomposition of the wood. Such treated wood is well known and is conventionally available. Such foundation walls usually include at least one bottom plate, and may be wrapped in plastic and then laid on an aggregate stone base. Timber foundations have several advantages, including allowing a manufacturer of such timber foundations to manufacture sections of such a wall in the controlled and enclosed environment of a manufacturing facility, whereby the sale and delivery of such a product is generally insensitive to weather conditions. . In addition, wood offers beneficial speed in building a building.

The main problem with wood foundations is that wood foundations are not well received by the consuming public, as the public does not perceive quality in a building where wood is used in a below average application. Lightweight structural building panels, for example generally continuous wall panels of any desired length up to a maximum length per panel, selectable in length, height and thickness, whose structural building panels are required in the construction industry, are required. may be used in applications where concrete is conventionally used in light, light commercial, and residential industrial construction, and whose structural construction panels are strong enough to withstand both the compressive loads and the lateral loads that are normally imposed on such walls. of concrete in a building structure.

Walls having superior water and moisture barrier properties are also required.

Walls that can be installed to be ready to support the above building structure in a short period of time are still required.

Further, walls are required which can be installed at a lower life cycle cost.

Accessory walls are also required to support another structure supporting such wall sections, and to serve as connectors between such wall sections and such another structure.

These and other needs are mitigated, or at least mitigated, by the novel construction products and methods of the invention.

SUMMARY OF THE INVENTION

The invention represents a rugged, waterproof construction system providing floor, ceiling, and wall building panels and wall sections, ceilings and ceiling sections, and corresponding floors and floor sections. The walls have both sufficient vertical compressive strength and horizontal bending strength so that the wall system can be used in both above average and below average structural construction applications, including applications where such Wall systems are exposed to severe wind and other climates, such as hurricanes, tornadoes, and the like. Such walls can replace concrete, and can meet strength specifications required for use in single family home, light commercial, and light industrial applications.

Similarly, ceilings and floors made of building panels of the invention have vertical and horizontal loading capacities capable of supporting the loads normally imposed on ceilings and floors in single family, light commercial, and light industrial residential construction.

A wall structure of the invention has an outer waterproof layer, comprised of reinforcement fibers incorporated in polymeric resin, which define the outward facing surface of the panel. Several fiber reinforced polymeric structural reinforcement members extend the full height of the erected wall panel and extend from or near the inner surface of the outer layer to a location at or near the inner surface of the wall structure, at spaced locations along the length of the wall panel. A weave such as reinforcement layer may weave back and forth between the inner and outer surface areas of the wall structure, and may form at least a portion of the inwardly facing surface of the wall structure.

The inwardly facing surface of the wall structure, considered in an orientation in which a wall panel is installed as a vertical wall in a building, may be formed of an inner structural reinforcement layer of fiber reinforced polymeric material (FRP), whereby the reinforcement layer is entirely enclosed between the inner and outer layers.

Any or all of the inner layer, the outer layer, and the reinforcement elements may be understood as fiber reinforced resinous structures or as resin impregnated fibrous structures. Both the materials description approach recognizes the structural contribution of both fiber and resin to the desired physical properties of the panels, as well as the benefit of having both materials in the panel / wall structure.

Optionally, a reinforcement pin is attached to or overlaid by the inner layer and extends into the building beyond what is otherwise the inner surface of the building panel / wall panel. The pin may originate from both the inner layer and the outer layer.

The spaces between one of the structural reinforcement element, and between the inner and outer layers, are optionally filled with rigidly insulated foam material such as polyurethane foam or polystyrene foam, or polyisocyanide foam. Any of a wide variety of stiffening, stiffening materials can be used as the structural reinforcement element to provide hardness, stiffness to the structural building panel. Each material individually has its own structural characteristics that drive desired cross-sectional shapes of the respective materials. Relatively more advantageous materials have insulation "R" values greater than 0.5, usually greater than R10.

The structural reinforcement elements are attached to or form portions of both the outer layer and the inner layer of the structural building panel, either by cured resin bonding or adhesive bonding, or being integral with the inner and outer layers by which reinforcement elements of the structural reinforcement elements extending between the inner and outer layers function in a similar capacity to the I-beam weft, and internal and external regions of the structural reinforcement elements, or the portions associated with them. the inner and outer layers, work in capacities similar to the operation of flaps of such beam in I. The effect of beam in

I overall provides, in a straight wall panel, or wall, both horizontal bending and vertical compressive strength sufficient to support both vertical compressive loads, and lateral side loads, for which building walls are designed, and they can provide such sufficient strength levels in cross sections that are not larger than the steel reinforced concrete wall cross sections that are conventionally used in such applications, while avoiding the disadvantages of concrete.

The structural reinforcement elements may be, for example, a continuous backward weaving layer between the inner and outer layers, or discrete foam block covers, or integral portions of reinforcing pins extending inwardly from the nominal inner surface, or may be integral with the inner and outer layers, as in a pultruded structure.

A foundation wall of the invention may be placed directly on a level bed of aggregate stone as a base. Alternatively, foundation walls of the invention may be placed on a poured concrete base, with a suitable gasket seal between the concrete base and a lower surface of the foundation wall, to accommodate deviations in the upper surface of such concrete base. Still further, the base may be elongated support wedges made of fiber reinforced polymeric materials described herein for use in the construction of the building panels of the invention.

The building panels of the invention may be used in below average applications such as foundation walls and opaque walls, in above average applications such as sidewalls of buildings, and for example ceiling, roof, and floor applications.

The invention further comprises resin impregnated fiber layers being formed using multiple layers to produce foundation wedges that serve as bases supporting columns, walls, and other overlying structure. The invention further comprises resin impregnated fiber layers being formed within supporting columns and columns supporting for example horizontal beams. Support columns and columns typically support specific and generally insulated loads such as fireplaces, saunas, large containers of water, and the like, as well as horizontal beams extending along the length or width of a building or a portion of a building.

Columns may be conventional, for example tubular steel columns, or optionally resin-impregnated fiber-based columns optionally tubular, for example fiberglass columns. A corresponding structural fiber-based cap at the top of any column spreads an overlying load generally around the perimeter sidewalls of the column. A downwardly dangling structural edge on the lid retains the lid against lateral movement relative to the top of the column.

The invention further comprises constructing an annex to a building outside the general perimeter of the building. Such typical attachments are decks, courtyards, light columns, piers, and the like which may function in combination with, or in association with, construction while being supported from separate and distinct foundations. An edge of such an attachment may in some cases be connected to the construction such as nails, bolts, screws, or the like. However, such attachments typically respond to environmental changes such as temperature changes at different rates than enclosed constructions for which the attachment is normally free-floating relative to the construction, ie the attachment is not attached to the construction with any fasteners.

Still further, the invention comprises, in addition to the support wedges, support columns, and covers, a variety of support structural members assisting in the transfer of forces to and from the wall panels. Such structural support elements may include support brackets which may support, for example and without limitation, brick fascia, floor edges, and floor lock ends. Such structural support elements may also include anchor brackets, connector brackets, corner brackets and variable angle brackets, as well as other support elements.

The invention understands that when constructions and other structures are constructed using the inventive structural elements described herein, such constructs, and other structures themselves, as well as relative substructures and subgroups that are related to such constructs and structures, are inventive.

The invention generally encompasses methods for manufacturing building panels as both defined length and continuous length panels in environmentally controlled manufacturing facilities. The building panel has a defined thickness and a defined width / height. A continuous length panel thus manufactured can be cut to any desired length in the manufacturing facility. As such, wall panels can be delivered from the manufacturing facility in a variety of lengths. In addition, a variety of panel widths / heights can be supplied from the manufacturing facility as desired. In addition, the panels can be cut as needed at the construction site such as to create gross window and / or door openings.

An exemplary method for making such building panels comprises depositing a first outer layer of the building comprising a first resin-impregnated fiber substrate on a generally horizontally extending transport support; placing foam blocks at spaced locations along the length of the first layer; depositing a second normally endless weave layer comprising a curable resin impregnated second fiber substrate on the combination of foam blocks and the first resin impregnated layer; placing additional foam blocks in the spaces and on portions of the weave layer, to generically fill in the spaces between the foam blocks and to define a generally consistent thickness of the resulting structure along the length and width of the resulting construction, and to develop a generally flat upper surface of the resulting construction; depositing a third inner layer comprising a third curable resin impregnated fiber substrate onto the upper surface of the resulting building thereby defining a second outer surface of the building panel opposite the first outer surface, and to thereby develop a non-precursor precursor. cured to the building panel; cure the resin in the first, second, and third layers; and cut

the generally continuous length building panel is thus made of individual panels each having a predetermined length and a predetermined width so as to define individual building panels each having a predetermined length and width dimensions. The dimension, which represents the width dimension of the building panel in such a horizontally oriented manufacturing process, becomes the height dimension of the building panel when the panel is oriented in a vertical orientation such as a foundation wall, a opaque wall, or a side wall, of a building.

In general, the invention comprises methods for producing building panels, comprising depositing a first fiber rich layer on a support, the first fiber rich layer having a width defined by the first and second edges, a length direction, and an upper surface. ; placing foam blocks over the first layer, lengths of the foam blocks extending generally between the first and second side edges of the first fiber rich layer; depositing a second fiber rich layer over the combination of the first fiber rich layer and the foam blocks, to thereby develop an uncured precursor in the building panel; and curing the uncured precursor to the building panel to thereby produce a generally rigid structural building panel. Alternatively, the invention comprises producing building panels of the invention by pultrusion processes, optionally including injecting foam material into the pultrusion product both during pultrusion product manufacture and after the pultrusion product has been manufactured.

The invention further comprises methods for constructing buildings, comprising constructing a building or building attachment, the method comprising excavating a hole to establish a natural base on which the structure is constructed; establish plant locations where vertical walls or other frame supports are erected; establishing a fabricated base, optionally a fiber reinforced polymeric base, along the locations left outside the supports; placing prefabricated load-bearing polymer-reinforced building panels or other supports on the fabricated base; connecting the prefabricated wall panels or other brackets together if and as desired thereby developing load bearing walls or other brackets; and raising the overlying structure over the load bearing walls or other supports.

BRIEF DESCRIPTION OF DRAWINGS

FIGURE 1 shows a representative illustrated view, with portions removed, of a building foundation wall fabricated using building system structures of the invention.

FIGURE 2 is a fragmentary interior view of a section of one of the straight wall structures shown in FIGURE 1. FIGURE 3 is a cross-sectional elevational view of the straight wall structure taken at 3-3 of FIGURE 1.

FIGURE 4 is an external elevational representation of the straight wall structure of FIGURE 3.

FIGURE 5 is a plan view of a straight wall section of FIGURE 2.

FIGURE 6 is a cross-sectional plan view of a portion of the wall frame taken at 6-6 of FIGURE 2.

FIGURE 7 is a plan view cross-section of a portion of a foundation wall according to a second embodiment of the invention.

FIGURE 8 is an enlarged plan view cross-section of a portion of the foundation wall structure of FIGURE 7.

FIGURE 9 is a cross-sectional elevational view of the foundation wall structure illustrated in FIGURES 7 and 8.

FIGURE 9A is an elevational view cross-section as in FIGURE 9 illustrating a different arrangement for supporting an overlying floor.

FIGURE 9B is an enlarged view of an upper portion of the structure shown in FIGURE 9A.

FIGURE 10 is a fragmentary illustrated view showing a foundation support shim of the invention supporting a conventional support column supporting an I-beam as in a below average foundation location.

FIGURE 10A is a cross section of a layered support shim illustrated in FIGURE 10, shown on an underlying rock or ground support base.

FIGURE 10B is a cross-sectional view of a pultruded support pad illustrated in FIGURE 10, shown 5 above an underlying ground support rock.

FIGURE 11 is an illustrated view of a square resin-fiber composite support column and resin-fiber composite lid of the invention supported by a square resin-fiber composite support shim of the invention.

FIGURE 12 is an illustrated view of a square resin-fiber composite support column and resin-fiber composite lid of the invention supported by an upwardly tapered square resin-fiber composite support wedge of the invention. invention.

FIGURE 13 is an illustrated view of a round resin-fiber composite support column and resin-fiber composite cap of the invention supported by a circular resin-fiber composite support shim.

20 of the invention.

FIGURE 14 is an illustrated view of a round resin-fiber composite support column and resin-fiber composite cap of the invention supported by a circular tapered upward resin-fiber composite support shim of the invention. invention.

FIGURE 15 is an illustrated line drawing of a resin-fiber composite support bracket of the invention that may be mounted on top of a foundation wall of the invention as shown in FIGURE 9. FIGURE 16 is a development of illustrated line of one embodiment of a resin-fiber composite channel pin of the invention, the pin of which may be incorporated into a wall panel of the invention as illustrated in FIGURES 7-9.

FIGURES 16A and 16B are illustrated line development of second and third resin-fiber composite channel pin embodiments that may be incorporated into wall panels of the invention.

FIGURE 17 is an illustrated line development of a resin-fiber composite "H" connector of the invention that is used to connect the first and second wall sections in a straight line.

FIGURE 18 is an illustrated line development of a resin-fiber composite fixed angle bracket of the invention that may be used on internal and / or external surfaces of a wall section by connecting the first and second wall sections to a perpendicular angle.

FIGURE 19 is a line view of a resin-fiber composite adjustable angle bracket of the invention for external and internal wall surface connections, and is adjustable regardless of the angle at which the respective bracket panels meet. in a line of articulator.

FIGURES 20 and 20A are illustrated views of resin-fiber composite board anchor brackets useful near the top and bottom of wall panels of the invention for example for anchoring a top plate and / or a bottom plate to the panel. wall. FIGURE 21 is an illustrated line development of a resin-fiber composite floor and garage bulkhead support of the invention.

FIGURE 22 is a cross-sectional plan view of a joint in a wall of the invention joining first and second building panels of the invention using a connector "H" of FIGURE 17.

FIGURE 23 is a cross-sectional plan view of a joint on a wall of the invention joining the first and second building panels of the invention in a 90 degree corner utilizing the first and second fixed angle support connectors of FIG. FIGURE 18.

FIGURE 24 is a cross-sectional plan view of a joint on a wall of the invention that joins the first and second building panels of the invention in a 90 degree corner utilizing a single fixed angle corner bracket to provide control. both on the inner surface of the wall and on the outer surface of the wall.

FIGURE 25 is a representative elevation view of an exemplary process of the invention that can be used to produce building panels of the invention such as those illustrated in FIGURE 8.

FIGURE 26 shows a cross-sectional plan view of a building panel embodiment of the invention where channel pins are between the inner layer and the foam blocks.

FIGURE 27 is a representative elevation view of an exemplary process of the invention that can be used to produce building panels of the invention such as those illustrated in FIGURE 26. FIGURE 28 shows a cross-sectional plan view of a straight building panel of the invention where foam blocks are encased in pre-wrapped layers and cured of the fiberglass / resin compounds before being bonded to the inner and outer layers.

FIGURE 29 illustrates a fragmentary end elevation view of a building panel preform in a vacuum infusion process being used to fabricate a building panel of the invention using pre-wrapped foam blocks as in Figure 28 and an overlying inner layer as illustrated in FIGURE 6.

FIGURE 30 shows a cross-sectional view in another embodiment of a straight building panel of the invention where pre-wrapped foam blocks provide the reinforcement structure of the reinforcement element.

FIGURE 31 shows a cross-sectional plan view of yet another embodiment of a straight building panel of the invention.

FIGURE 32 shows a plan view cross-section of a first embodiment of non-insulated building panels of the invention.

FIGURE 33 shows a plan view cross-section of a second embodiment of non-insulated building panels of the invention.

FIGURE 34 shows a plan view cross-section of a third embodiment of non-insulated building panels of the invention.

FIGURE 34A shows a cross-sectional plan view of fragmentary portions of the first and second straight construction panels illustrating edge structures of the two panels.

FIGURE 34B shows plan view cross sections of first and second straight building panels illustrating edge structures including integral pins.

FIGURE 35 shows a cross section of a building panel of the invention incorporating the hollow pins of FIGURE 16B.

FIGURE 36 shows a cross section of a building panel of the invention assembled from elongated pultrusions, including pultruded pins, all generally rectangular in cross section.

FIGURE 37 illustrates a vacuum molding process for producing a building panel of the invention having pins extending inwardly from the main inner surface of the building panel.

FIGURE 38 shows a cross section of a building panel incorporating pins illustrated in FIGURE 16B and utilizing the process of FIGURE 37.

FIGURE 39 shows a side elevational view, with portions cut out of a portion of a fourth uninsulated building panel of the invention.

The invention is not limited in its application to the details of construction, or the assembly of components set forth below in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or performed in various other ways. In addition, it is understood that the terminology and circumlocution employed herein is for description and illustration purposes and should not be construed as limiting. Similar reference numerals are used to indicate similar components.

DETAILED DESCRIPTION OF ILLUSTRATED MODES

Referring to FIGURE 1, several interior and exterior foundation walls 10 collectively define the foundation 12 of a building. Each foundation wall 10 is defined by one or more foundation wall panels 14. In the illustration, each foundation wall panel 14 includes a lower plate 16, a straight wall section 18, and an upper plate 20. Each section of straight wall 18 includes a main passage wall section 22, and vertically oriented reinforcing pins 23 attached to or integral with the main passage wall section, regularly spaced along the length of the wall section, and extending into the inner surface of the main passage wall section. In the embodiment illustrated in FIGURE 1, anchor wedge-shaped brackets 24 are mounted on the pins in the upper and lower portions of the wall section to assist in anchoring the lower plate and upper plate, and / or any other. attachment to the main through portion of the straight wall section.

As illustrated in FIGURE 1, conventional I-beams 26, for example steel, are mounted to the wall sections as needed to support wings of overlying floors. Such steel I-beam may be supported at one or more locations along the I-beam span, as required by both conventional columns, e.g. steel, and resin-fiber composite 28 columns of the invention ( 1 and 10) and / or resin-fiber composite shims 30 (FIGURES

1 and 10) of the invention. Additional support columns may be employed at or adjacent to the ends of the I-beams as required to meet individual load bearing requirements specific to the construction project. Fiberglass reinforced brackets, or solid reinforcement pins 23 (FIGURES 5-6) or hollow channel pins 123 (FIGURES 7-9 and 16) or conventional eg steel supports may be used to secure the beams to I to respective panels of the foundation wall for example conventional steel bolts. Pins 23 are cut as needed to support the I-beam at the desired height. Multiple pins can be used side by side as needed to provide the desired load bearing capacity.

Referring now to FIGURES 3, 5, and 6, the main through wall section 22 is generally defined between the inner surface and the outer surface of the wall panel, without considering the thickness on pin 23. The through wall section The main method thus generally includes a foam core, and the inner and outer layers 34 of fiberglass reinforced polymer (FRP), otherwise known as fiberglass sheets or fiberglass layers. The foam core may be foamed in place of thermal insulating material between the prefabricated inner and outer layers, or may be made from prefabricated blocks 32 of thermally insulating foam material, the blocks of which are assembled, for example when using adhesive or curable resin, with the remaining elements of the respective wall panel as described hereinafter in further detail. Bottom plate 16 and top plate 20 may be attached to the main through section with the wedge-shaped support bracket 24 (FIGURE 2), or other supporting support structure, optionally in combination with adhesive or curable polymeric resin. additional. Adhesive selection depends on the selection of the material from which the top plate is made, as well as the specific material forming the respective face of the wall panel, and the material from which the support 24 is made. An exemplary adhesive is Pro-Series QB-300 Multipurpose Adhesive, available from OSI Sealant Company, Mentor, Ohio. Such an adhesive may be used as desired to hold various members of the building panel assembly together.

The foam core layer is of sufficient density, stiffness, and polymer selection to fix the positions of the fiber reinforced polymer layers at their respective positions as illustrated. Thus, in the embodiments illustrated in FIGURES 3, 5, and 6, the rigidity of the foam contributes significantly to the dimensional stability of building panel 14. In addition, the foam provides substantial thermal insulation between the inwardly facing surface of the wall and the surface

that faces out of the wall.

The bottom plate 16 may be a structural member.

fiber reinforced, for example fiberglass reinforced polymer of such dimensions as are sufficiently rigid and of sufficient strength to support both the foundation wall and the superstructure of construction from a defined underlying fabricated base for example, a nodded bed 53 (FIGURE 9) of aggregate stone, from an underlying fabricated base comprising a concrete base 55 (FIGURE 3), or from another suitable underlying fabricated support base. The specific structural requirements of lower plate 16 depend on the loads to be applied.

A pultruded fiber reinforced product, for example, between 1.9 mm and approximately 13 mm in thickness, has been found to be satisfactory as the backplate for normal multi-purpose and light industrial, light commercial, and single family residential construction.

The bottom plate may be attached to the straight wall section, and optional support brackets 24 by adhesive, curable resin such as that used in the wall panel, by steel bolts extending through a vertical member of the bottom plate, for example, adjacent to the outer surface of the straight wall section and through the adjacent portion of the straight wall section, or by a combination of metal and adhesive anchors and / or resin or other fastening mechanism. In any event, the bottom plate, when attached to the straight wall section, is sufficiently wide, thick, dense, and rigid to provide effective compression and folding support to thereby support the foundation wall from the underlying ground and / or stone and / or rock, and other natural base although usually

through a fabricated footing.

The bottom plate usually extends laterally

into the building beyond the primary surface of the inner layer by a distance corresponding to at least the maximum thickness of the building panel including pin 23 to thereby provide a bearing surface suitably sized to the underlying support base by which the overlying load It may be supported by the underlying support base without causing substantial movement in the underlying support base of the soil, stone, or rock. Alternatively, the lower plate may extend outwardly from the building panel, away from the construction to provide the suitably sized bearing surface cited, or may extend both inwardly and outwardly from the paneling.

construction.

The top plate may be made of fiberglass wrapped layers, may be a pultruded resin-fiber composite, may be conventional wood, or a manufactured wood product, or other conventional construction material, each of such structures being sufficiently wide and thick to provide a supporting surface, which interfaces with the underlying straight wall section, and from which the overlying superstructure of the building can be supported. The top plate may conveniently be made from wood building materials whereby the overlying building structures may be conventionally attached to the underlying foundation wall structure on the building side by use of conventional fasteners,

conventionally fixed to the upper plate.

The combination of the inner and outer fiberglass layers 34, 36, and reinforcement pins 23, for example 2x4's, 2x6's wood, as illustrated in FIGURE 6, is strong enough to withstand inwardly directed side forces, for example, folding walls, which are imposed on a foundation wall by the ground, or walls above the ground by wind loads, both imposed from the outside of the building.

A suitable illustrative base may be made from aggregate stone, illustrated as 53 in FIGURE 9 or concrete as illustrated in 55 in FIGURE 3. A suitable aggregate stone has a size that passes through a 2.54 cm mesh and does not pass. through a mesh of

1.90 cm.

Referring to FIGURES 1, 3, and 9, once the foundation wall 10 is in place as shown in FIGURE 1, on a suitable base (53, 55), a ready-mix concrete slab floor 38 is poured. . The concrete slab floor extends over, and thereby overlaps, that portion of the lower plate 16 extending inwardly from any inner surfaces of the wall panels, including both pins 23 and the main through wall section. . That is, the concrete slab floor extends to and abuts against the inner surfaces of the respective straight wall sections 18. Consequently, once the concrete slab floor is cured, inwardly directed side forces are imposed by ground outside the building at the bottom of the wall, and taken in a direction aligned with the width of the bottom plate 16, are prevented, opposite, nullified by the structural compressive strength, eg side / side of the floor slab of concrete 38 on foundation wall support 10 as the edge of the slab abuts the inner surface of the foundation wall. In this way, inwardly directed side forces that are imposed on the adjacent lower foundation wall plate 16 are ultimately prevented, and absorbed, by slab 38.

Inwardly directed side forces that are imposed on the foundation wall at or adjacent to the upper plate 20 are transferred to the main floor 40 the building (FIGURES 3, 9, and 9A) for example by conventional mechanical fasteners and standard construction techniques which mechanically secure the main floor 40 and the foundation wall 10 together, or otherwise cause the main floor and foundation to act

cooperatively together.

Still in relation to the main passageway wall section 22 (FIGURES 1, 3, and 6), and considering the structural environment of story-1 and story-2 residential construction, and where foam blocks 32 make substantial contributions to the dimensional stability of the In the panel, the inner and outer fiberglass reinforced layers 36 are, for example, between 0.75 mm and approximately 3.8 mm thick. Thicknesses of inner layer 34 and outer layer 36 are generally constant between those of reinforcement pins 23. Outer layer 36 may be reinforced for example to achieve the ability of the wall to withstand the imposition of directed loads.

laterally over the wall.

In the embodiments illustrated in FIGURES 1-6, pins 23 run the full height of the main wall section, and extend from the inner surface 42 of the outer fiberglass layer 36, or the inner surface 52 of the fiberglass layer. inner glass 34, inward and / or outward, a desired distance in order to provide the desired level of structural strength to the wall panel 14. In the embodiments illustrated in FIGURES 1-6, the inner fiberglass layer 34 is wrapped around the inwardly facing surface 44 of the pin. Wrapping the fiberglass layer over the pin as illustrated for example in FIGURE 6 provides a waterproof coating to a wooden pin e.g. without limitation, a 2x4 pin, a 2x6 pin, a pin 2x8 or other dimension pin in order to make the pin waterproof and insect proof. At the same time, the fiberglass layer wrap incorporates the pin into the main wall section frame unit, whereby the bending strength of the pin significantly contributes to the overall bending strength of the assembly defining the structure. Main passage wall section. Thus, pins 23 act as reinforcement elements in wall panel 14.

Compared to, for example, a wall section of 5.08 cm in thickness, 2.44 m in height, which has no reinforcement element, a corresponding wall that incorporates 2x4 pins on centers of 60.96 cm, wrapped about 3 sides by the inner layer as shown, exhibits approximately 25% increased bending strength. Such bending strength is measured by applying a linear load that traverses the length of the wall panel at half height of the wall panel, and whose load is opposed by blocking linear opposition of corresponding lengths at the top and bottom of the wall panel.

Referring to FIGURE 6, when designing the main passage wall section, both the lateral strength of such a straight wall section, and the compressive strength of such a wall section, may be reinforced as desired with for example section reinforcements ". T "46, or the like, which normally extend the full height of the main passage wall section. A provided "T" section reinforcement has a tab 47 extending generally parallel to the outer layer 36 and a web extending transverse to, generally perpendicular to the outer layer 36. The web 49 normally extends through at least at least half the distance between the inner layer and the outer layer. "T" section reinforcements 46 can be made of any desired material that can contribute significantly to the structural strength of the wall section. Such normal "T" section reinforcements may be steel fiber reinforced polymer compositions such as resin impregnated fiberglass structures or fiberglass reinforced pultrusions, or the like.

Flap 47 of section "T" may be positioned against both the outer layer 36 as shown and against the inner layer 34. In either case, the web 49 extends inwardly through the thickness of the wall panel from the surface. respective inner or outer layer. The surface of the flap 47, which faces the inner surface of the respective inner or outer layer, is bonded, for example, adhesively bonded, to the respective inner surface of the inner or outer layer. As an adhesive, the respective known building adhesives may be mentioned. In some cases, the curable resin that is used in producing the respective inner or outer layer is also effective in securing the "T" section flap 47 to the respective inner or outer layer. Where the "T" section is placed against the outer layer 36, the "T" section may be provided with fasteners that secure additional layers, such as siding, to the construction toward the outside surface of the wall panel.

In place of wT "section reinforcements, a wide

A variety of other elongated structural constructions 46 may be incorporated within the wall panel. Like other cross-sectional constructions, there may be mentioned, for example and without limitation,

cross section representing elongated perpendicular angle 2-member constructions that eliminate half of the flap 47 shown in FIGURE 6, elongated square tubes, "Η" section structures, "U" section structures, "I" section structures , and the like. Such a construction

20 may comprise multiple frames 49 spaced along the

panel length and connected to one or more tabs 47.

Typically, the number of such structural constructions 46 is no greater than the number of reinforcing pins 23, or the like, which run the full thickness of the cross section.

Main passage wall.

As desired, section "T" or other structural constructions 46 may be omitted, whereby resistance to, for example, gravitational compressive forces and lateral forces on the wall panel is derived.

30 enormously from inner and outer layers 34, 36, and pins / reinforcing elements 23 and where fasteners are directed to pin 23.

FIGURE 6 illustrates in dotted outline a wedge-shaped pin reinforcement made of for example a resin-fiber composite. Such wedge-shaped reinforcements may be added to the wall cushion structure for additional sidewall resistance, in pins 23.

Pins 23 may be conventional wooden pins as illustrated in FIGURE 6, or may be made to wrap for example, concentric layers of resin impregnated fiberglass sheet over themselves until the desired cross-sectional shape is obtained. Alternatively, pins may be fiber-reinforced pultruded structures, both hollow and solid structures, i.e. any elongated structural cut-off providing desired spatial and structural properties.

Still with reference to FIGURES 1-6, in general, the inner and outer layers of the wall section are fiberglass reinforced resin sheets, full height and full length of the wall section. The inner and outer layers 34, 36 are for example between about 0.075 mm and about 3.8 mm in thickness, optionally between about 0.75 mm and about 2.5 mm in thickness. Foam blocks 32 fill the entire space between the inner and outer layers 34, 36 except for the pins, where the pins usually fill the entire space, for example, the full thickness of the wall section between the inner and outer layers, with the foam filling the other space between layers 34 and 36.

The wall section thickness "T" (FIGURE 8) in the main passage wall section is defined without regard to the dimensions of pins 23 or 123, and generally stops at surface 25 of which is later defined here as space 131. Thickness " T "may be as small as approximately 5.08 cm between the inner and outer surfaces of the wall, up to as much as approximately 20.32 cm or more as measured between the outer surface of layer 34 and the outer surface of layer 36, and which ignores pins 23 for "T" thickness setting purposes. Normal wall thickness is between approximately 7.62 cm and

approximately 15.24 cm.

The upper plate and the lower plate may be conventional, for example, wood materials, with suitable waterproof feature as appropriate for the intended use. In order to avoid moisture contact issues with wood, the bottom plate is typically a fiberglass reinforced resinous compound of sufficient thickness and stiffness to provide the anticipated weight bearing capacity as needed to support the structure. to be sustained.

As used herein, all fiberglass composite / resin structures, such as bottom plate 16, top plate 20, pins 23, and the like, can be fabricated using known fiberglass pre-impregnated batt construction and handling techniques. glass or dry, and resin impregnation of such materials, cut spray processes, vacuum infusion processes, 30 pultrusion, or other known processes for producing fiber reinforced compounds to produce the desired three-dimensional shapes. Such techniques may be used, for example, to produce lower plate 16, to produce pins 23, the wedge-shaped pin extensions illustrated in dotted highlighted FIGURE 6, or wedge-shaped brackets 24, and the like.

Structural building panels of the invention may be manufactured in any of the standard dimensional sizes as well as in a variety of other desired size combinations for a specific building project. Thus, for example and without limitation, such panels may have heights of approximately 1.22 m, which accommodate the use of panels on 1.22 m opaque walls. The height of approximately 2.74 m accommodates the use of the panels in standard height foundation walls and walls above

standard height average.

The thickness of the panels usually varies between

approximately 7.62 cm in nominal thickness and approximately 20.32 cm in nominal thickness. At least 7.62 cm is usually desired in order to obtain the required bending strength as well as desired thermal insulation properties. However, additional bending strength can be obtained by using outwardly extending pins from nominal thickness. In addition, additional thermal insulation properties can be obtained by adding conventional insulating material between studs on the inner surface of the panel.

Normally, thickness greater than 20.32 cm is not required in order to satisfy structural demands of

30 demands of thermal insulation. However, in some cases, where extraordinary thermal or structural demands must be imposed on building panels, then thickness greater than 20.32 cm is contemplated.

Panel lengths are limited by transport limitations only. For example, such panels may be as long as the length of the truck bed that will transport the panels to the construction site. As such, the length is usually limited to approximately 12.2 m, but may be longer as desired where adequate transportation is available. However, since an advantage of the panels is limited weight so that the panels can be installed below average and grid level without the use of a crane, the length is limited in some embodiments to lengths that can be readily handled by lifting. manual. Therefore, the lengths are not normally longer than approximately 12.2 m based on the weight that can be accepted for manual lifting of the panels.

On the other hand, where a crane is used, and where adequate transportation is available, the panels may be as long as desired for the intended purpose.

Structural building panels of the invention provide several advantages. For example, structural building panels may be manufactured to a continuous length, and except for transportation, at any desired length, which may be a generic length, for example, 3.05 m, or 6.10 m, or 12, 2 m, or any length or lengths are desired. The length required for a specific portion of a building wall can be cut from a generic length building panel at the construction site to meet specific needs, or it can be cut to specific length at the panel manufacturing site. Thus if a shorter length is required for a specific portion of the wall passage, the required length can be cut for example from a 6.10 m section or from a continuous section. If a longer length part is required, either a longer length panel can be fabricated or a unitary product at the panel manufacturing site, or two pieces can be joined using suitable straight-through connectors, or corner connectors as appropriate for the specific set to be made. The respective building panels may be cut to length, for example using a circular saw, a ring saw, or an alternative saw, which employs, for example, a mansory blade, and is mounted on site.

Since the wall assembly is mainly derived from fiberglass, resin, and foam, the density of pounds per cubic meter, and thus the unit weight per meters in length is relatively small compared to a correspondingly sized concrete wall. . For example, a 6.10 m long, 2.44 m high, and nominally 7.62 cm thick building panel weighs approximately 104.32 kg, including pins 23, and anchor supporters discussed elsewhere herein. .

Similarly, a 2.74 m high wall weighs approximately 4.5 kg (10 pounds) to approximately 6.8 kg per linear meter (15 pounds). Consequently, no crane is required on site to raise a wall at or near ground level, or below ground level such as for a foundation wall. Instead, such wall panels can be readily moved by manual labor only. In fact, 2-4 workers can lift by hand and position a normal wall section that is 6.10 m long, 2.44 m high, and 7.62-12.7 cm thick. " Gross openings for windows 27 and / or doors 29, illustrated in FIGURE 1, may be cut in place using the mansory blade noted above. Fittings, and other connections between wall elements and between the wall and other building elements, can be moved by drilling and locking conventional building construction elements to the building panel, or by using panel self-tapping fasteners. in

construction, or by adhesive.

FIGURES 7-9 depict a second embodiment of wall and wall structures of the invention having a second structural expression of extending the reinforcement structure through the thickness of the wall panel. FIGURE 7 is a top view of a portion of a foundation wall including a 90 degree corner in the foundation wall. FIGURE 8 is an enlarged cross-sectional view in a plan view of a portion of the foundation wall shown in FIGURE 7. FIGURE 9 is an elevational view cross-section of a portion of the foundation wall shown in FIGURES 7 and 9. 8

FIGURE 7 shows that a substantial portion of the foundation wall volume is occupied by the low density insulating foam block series 32. As in the embodiments of FIGURES 1-6, the inner 34 and outer layers 36 of fiberglass reinforced resin form the generic inner and outer layers of the wall panels 14.

As best seen in FIGURE 8, pins 23 are omitted, and at least part of the pin reinforcement function 23 is provided by a continuous reinforcement weave layer 50. The weave layer 50 weaves back and forth of a from the inner 34 and outer layers 36 to the other inner and outer layers between each of the foam blocks 32, i.e. at spaced transverse locations spaced along the length of the building panel. Such intersections are usually spaced from each other along the length of the building panel between about 10.16 cm and about 60.96 cm, usually between about 15.24 cm and about 3.48 cm. Most commonly, the foam blocks are approximately 20,32 cm wide so that the intersections are spaced approximately 20,32 cm apart. As with the inner and outer layers, for conventional residential single-family construction, the weave layer at intersecting locations has a nominal thickness between approximately 0.76 mm thick and approximately 0.35 cm thick.

Thus, with respect to FIGURE 8, the weave layer 50 extends from left to right along the inner surface 42 of the outer fiberglass layer 36, between the layer 36 and a foam block 32A to the edge. of width "W" of foam block 32A. Still with reference to FIGURE 8, at the right edge of foam block 32A, the weave layer 50 turns at an angle of 90 degrees and extends to the inner surface 52 of the fiberglass layer 34. On the inner surface 52 of the foam layer Inner fiberglass 34, the weave layer rotates another 90 degrees, and extends right along the inner surface 52 of the inner fiberglass layer along the full width of foam block 3B, then turns and again returns to the inner surface of the outer fiberglass layer 36. The weave layer 50 thus follows a round trip between the inner surfaces 42.52 of the outer layers 34, 36 along the length. of the respective wall panel 14. The layer 50 is in surface-to-surface contact normally complete with the respective layers 34 and 36, and the respective foam blocks 32, all or substantially all of their way and along from sub substantially all portions of the respective facing surfaces of layers 34 and 36, and foam blocks 32.

The respective layers 34, 36, 50, and foam blocks 32 are all integrally bonded together to produce a unitary compound structural product. Thus, the weave layer is attached to the respective elements of both inner and outer layers, whereby the thickness of the inner and outer layers, as combined with the weave layer, vary between relatively substantially thicker portions and relatively substantially larger portions. Thin. Usually the relatively thicker portions of the combined layers 34, 50 and 36, 50 are at least 50 percent thicker than the relatively thinner portions of the layers 34 and 36. The resulting composite product functions much as an I-beam where layers 34 and 36, and combined elements of layer 50, serve as flap elements of the I-beam structure, and the crossover portions of the weave layer 50 function as weft elements of such structures.

beam type in I.

Foam blocks provide a thermal insulation function. In addition, foam blocks 32, together with the agglutination of the respective elements together, and the absence of substantial voids in the wall structure, serve to secure each layer 34, 36, and 50 in position along its intended transverse path. , relative to the remaining elements of the structural building panel, thereby uniting the layers 34, 36, 50 and blocks 32 into a single structural product where the respective elements cooperatively respond together, in support of one another, sharing between each other respective portions load when external forces are imposed on the control panel.

structural construction.

In general, the entire space between the inner surface 57

of the panel and the outer surface 56 of the panel is occupied by one of the layers 34, 36 and 50, or by foam blocks, whereby little, if any, of the space between the layers 34 and 36 is not occupied by one of the layers. panel materials cited above. Normally, substantially all of the internal space is occupied. Thus filling the space between the layers 34, 36, all panel elements are fixed in their relative positions to each other, and the panel is dimensionally well stable under projected load, whereby specially directed laterally imposed loads on the panel from outside. of construction, both underground and above average ground loads e.g. wind loads, are efficiently transferred from the outer layer 36 to the other panel elements, and respective portions of layers 34, 36, and 50, and multiple foam blocks, share on the support of any load. The resulting panel is inflexible, rigid, and strong enough to withstand all loads, including severe weather loads, which construction is normally expected to undergo under normal use environments, including seasonal environmental extremes in the environment.

geographic location provided.

FIGURES 7, 8, 9, and 16 also show several

Resin-impregnated hollow fiberglass reinforcement channel pins 123. A respective hollow channel pin 123, as shown, is a unitary structure having first and second flaps 126 that interface with the outer surface of the inner layer 34. The flaps 126 are bonded to the inner layer 34 either through the resin forming part of the layer 34 or through a separate adhesive or resin layer that binds the flaps to the layer 34. Straight members 128 extend from flaps 126 to an end panel 130. The end panel 130 forms the surface of the channel pin extending to the greatest extent into the interior of the building, and away from the outer surface 56 of the building panel. In the panel assembly, a hollow space 133 is defined within a respective pin 123. The hollow space 133 is enclosed by the combination of end panel 130, members 128, and both inner layer 34 and FIGURES 8 and 28 as a block. of foam 32 as in FIGURES 26 and 29.

Flaps 126, members 128, and end panel 130 generally form a unitary structure. The channel pin structure 123 may be relatively thin, for example end panel 130 and members 128 may be between approximately 0.75 mm and approximately 3.8 mm thick. Typically, the end panel is offset from the tabs by approximately 2.54 cm to approximately 13.97 cm, optionally between approximately 5.08 cm to approximately 8.89 cm. Even in the aforementioned such thin cross section, in light of the distance between the end panel and the tabs, pin 123 makes a significant contribution to the panel's ability to withstand lateral forces, for example bending forces imposed by ground forces, or forces. from outside the building.

Additional contributions to lateral drag strength can be developed by producing studs to a more robust structural specification or by placing a stiffening insert into the stud cavities. For example, pins 123 may be fiber-reinforced rectangular cross-section pins between approximately for example 1.8 mm and approximately

13 mm wall thickness.

Pins 123 serve multiple functions. As a first function, pins 123 serve as mounting locations for mounting surface materials such as sheet rock, paneling, or other interior sheet material 119, as illustrated in FIGURE 26, to form the interior finished wall surface as Busy living space. Still with reference to FIGURE 26, the spacing 131 between the pins provides channels for traversing and additional insulation 135, and / or utilities 137 such as electricity, plumbing, and / or piped air. Such utilities may also be passed internally within the hollow space 133 defined between an end panel 130 of a pin 123, and layer 34. Another major function of the pin is that the pin enhances both vertical compressive strength and momentum resistance. Horizontal point loading folding of the wall. Thus, in the embodiments of FIGURE 26, pins 123 and the crossover portions of the weave layer 50 may be collectively designed to provide the strength attributed to the structural reinforcement pin 23 of FIGURE 6.

FIGURE 16A shows a second embodiment of pins 123. In the embodiments of FIGURE 16A, the two outwardly disposed tabs 126 are replaced with a single connecting tab 126 that connects with members 128, whereby a pin 123 of FIGURE 16A represents an elongated enclosed rectangular body that encompasses the hollow space 133 and opens at opposite ends of the pin. Pins 123 of FIGURE 16A may normally be used anywhere pins of FIGURE 16 may be used. For example, such pins may be attached to the panel assembly at the top of the inner layer 34 as shown in FIGURES 8 and 28. For example, the pins of FIGURE 16A may be joined to the foam blocks, and the inner layer 34 applied over the pins as shown in FIGURES 26 and 29.

FIGURE 16B shows a third embodiment of pins 123. As in the embodiments of FIGURES 16 and 16A, pins 123 of FIGURE 16B are made by impregnating a resin fiberglass mat in a non-pultruded process and curing the resin. In the embodiments of FIGURE 16B, the two outwardly flaps 126 are replaced with a single connecting tab 126 as in the embodiments of FIGURES 16A, and the depths of the members 128 are extended compared to the members shown in FIGURES 16 and 16A. That is, the members 128 in the embodiments of FIGURE 16B are long enough that the pin can be mounted to the panel assembly on or adjacent to the outer layer 36. Thus, the pins 123 of FIGURE 16B can be mounted to the assembly. panel 123 in a configuration where pins 123 replace pins 123 shown in FIGURE 6. However, pins 123 are normally hollow, whereby the hollow space 133 extends from the outside of the building panel in layer 36 to the final panel 130. FIGURE 35 illustrates hollow fiber-reinforced polymeric pins 123 of FIGURE 16B grouped into one

building panel of the invention.

FIGURES 7-9, 20, and 20A illustrate plate anchor brackets 24 and 24A. A bracket 24 or 24A is mounted to the inner surface of inner layer 34 at the top of the wall panel, and is optionally also attached to pin 123 through a side panel 138. Line representations of brackets 24 and 24A are illustrated in FIGURES 2. 0 and 20A. Referring to FIGURE 20, the upper panel 136 of the support 24 extends transversely from, and is joined to, the upper portion of the base panel 134. The first and second side panels 138 extend transversely from, and are joined to both base panel 134 and top panel 136, thereby supporting top panel 136 from base panel 134, and supporting base panel 134 from top panel 136.

Base panel 134 of bracket 24 is positioned against inner layer 34 of wall panel 14 and is mounted on inner layer 34 and optionally mounted on pin 123 on side panel 138. Panels 134 and 138 may be mounted on inner layer 34 and pin 123 adhesively, or may be pressed into the inner layer 34 and / or pin 123 before the inner layer resin, or the pin resin, is cured, whereby curing of the resin in the inner layer or pin serves to bonding the panel 134 to the inner layer 34 and / or pin 123. The panel 136 interfaces with and supports the upper plate 20, and is normally latched to the upper plate as illustrated in FIGURE 9, whereby the support 24 serves to transfer loads between the top plate 20 and the main portion of the wall panel, so making the top plate a part

integral of the foundation wall.

As suggested in FIGURE 8, one of the side panels 138 is used to secure the support 24 to pin 123, while the base panel 134 is used to secure the support to the inner layer 34. Accordingly, the second side panel has no fastening function. , and may thus be omitted in some embodiments. Bracket 24A of FIGURE 20A illustrates such embodiment where bracket 24A is the same as bracket 24 of FIGURE 20, except that it provides only a single side panel 138.

FIGURE 9 illustrates, in side elevation view, the upper plate anchor support interface 24 with upper plate 20. In the illustrated embodiment, the upper plate is a conventional wooden board, and is secured to support 24 by a bolt 139 through Figure 9 also illustrates a second anchor bracket 24 used in supporting the interface between the wall panel and the bottom plate 16.

FIGURES 7 and 22 illustrate joining two wall panels 14A and 14B using a "H" connector bracket 140. A "H" connector bracket representation alone is shown in FIGURE 17. In the "H" connector bracket 140 , the first and second parallel tabs 142, 144 are connected at perpendicular angles to oppose the edges of an intermediate web 146. In some cases a single tab 142 or 144 may be used on both the inner and outer surfaces of the panels. that are being joined together. The surfaces of the wall panels 14A, 14B, and the connector support "Η", where the connector support "H" is in relation to surface to surface with wall panels 14A and 14B are joined together. Such agglutination can be achieved with known adhesives. Alternatively, the surfaces of the "H" connector bracket and / or wall panels may be coated with uncured portions of the curable resin, which is subsequently cured after the wall panels are joined with the "H" connector bracket in place. construction. Such curing may be accomplished with heat guns or the like if and as heat is a necessary element of curing the selected polymer resin composition.

FIGURES 7 and 23 illustrate the joining of two wall panels 14A and 14C using first and second corner supports 148 and 150. Each corner support has first and second panels 152 which are at an angle of 90 degrees in one corner. 154. A line representation of an angle bracket 148 alone is illustrated in FIGURE 18. Since only the difference between brackets 148 and 150 is the relative widths of panels 152, only bracket 148 is shown alone as in FIGURE 18. 18

The interface surfaces 152 of corner brackets 148, 150 and wall panels 14A and 14C in bracket panels 152 are bonded together. Such agglutination can be achieved with known adhesives. The supports 148, 150 may be held in place with e.g. self-tapping mechanical fasteners while agglutination is being achieved. Alternatively, the surfaces of the angle supports and / or panels may be coated with uncured portions of curable resin, which is subsequently cured after the panels are joined with the angle supports at the construction site. Such curing may be done with for example heat guns or the like if and as heat is a necessary element of such curing.

FIGURE 24 illustrates a support 160 that can be used as a single support corner construction. Bracket 160 has inner panels 152A as in brackets 148 and 150, and also has a connector panel 162 which connects the inner panels to the outer panels in the corner 154 where the inner panels 152a meet. FIGURE 19 illustrates a variable angle bracket 170 having rigid panels 152, and a flexible hinge area 172 that can be flexed at any included angle from about 0 degrees to about 180 degrees. Bracket 170 is used to join wall panels together where panels 14 are neither perpendicular to or aligned with one another. Once rigid panels 152 have been bonded to the surfaces of the building panels 14 being joined, and the building panels have been set at the desired included angle to each other, the flexible hinge area can be made rigid by applying to the area Hinge 172, a curable two-part hardening resin coating as used to produce building panels 14 and support panels 152. The same agglutination, and stiffening, can also be made using hardening construction adhesives of cure, conventional and well known.

FIGURE 9 illustrates, in edge view, the addition of a fiberglass / resin support bracket 48 (FIGURE 15) against the outer surface 56 of the wall. FIGURE 4 illustrates, from a side elevation view of the outer wall surface, the extent of the support bracket 48 as a brick protrusion along the full length of the main passage wall section. Bracket 4 8 transfers weight of overlying bricks 175

to the underlying wall 10.

Still with reference to FIGURE 9, a support bracket 48 extends outwardly from the outer surface 56 of the wall panel a sufficient distance, such as between approximately 10.16 cm and approximately 12.7 cm to support conventional brick or wall. stone that turns to the outside of the building. As indicated in FIGURE 9, upon completion of the construction work, earth or other backfill 174 typically fills the hollow excavated around the foundation wall to a level at or above the brick support panel 176, thereby covering the support 48.

The support bracket 48 may be installed by turning inwardly at the top of for example a garage wall, thereby providing a vertical edge bracket to a subsequently poured concrete garage floor. Similarly, the bracket 48 may be installed by facing outwardly at the top of for example a garage or other wall, thereby providing vertical edge bracket to subsequently installed brick or stone. The first and second complementary supports 48 may be mounted on top of each other with brick support panel 176 of the first support 48 facing away from the building and the brick support panel 176 of the second support facing into the building. Such use of two brackets provides wall bracket of both a garage floor joining edge and brick or stone exterior fascia, both of which are adjacent to the foundation wall.

A support bracket line representation 48 is illustrated in FIGURE 15. In the vertical use orientation illustrated in FIGURES 3, 9, and 15, a base panel 178 of support 48 is oriented vertically along the outer surface 56 of the control panel. construction 14, and may optionally be bonded to panel 14. Brick support panel 176 extends outwardly from the base panel above the bottom edge of the base panel. A brace panel 180 extends upwardly from the bottom edge of the base panel to the outer edge of the brick support panel, transferring upwardly directed structural support from the base panel to the outer edge of the support panel. brick. An upper panel 182 extends horizontally from the upper edge of the base panel and ends in a downwardly directed retaining panel 184. Top panel 182 and retaining panel 184 collectively mount / suspend the support bracket 48 from the surface. top of the wall panel 14.

FIGURE 21 illustrates a second embodiment of the support bracket, i.e. a two-sided support bracket which is designated as 188. Support 188 is designed and configured to support both (i) an edge of a garage floor that generally abuts the inwardly facing surface of the foundation wall and (ii) a brick or stone fascia that normally faces the outwardly facing surface of an upper portion of the foundation wall, as well as, for example, a wall above of the straight middle that overlaps the foundation wall. The edge of the garage floor overlaps a first support panel of the support bracket and thereby carries the support bracket over the inward side of the foundation wall. The stone or brick fascia overlaps a second support panel support panel and thereby carries the support support over the outside of the foundation wall. The loads imposed on the support panels are passed from the support bracket through the foundation wall to the base, and thus to the underlying ground or other natural base supporting the respective wall.

As with the support bracket 48, the two-sided support bracket 18 is installed on top of the wall panel so that the top panel 182 rests under the top surface of the wall panel. Base panel 178A extends downward from top panel 182. Support panel 176A extends downward from base panel 178A, and is supported by adornment panel 180A. A second base panel 178B extends downwardly from the top panel 182, usually but not necessarily a similar distance from the base panel 17A to terminate at a bottom edge that normally has the same elevation installed as the bottom panel. base 178A. Support panel 176B extends outwardly from base panel 178B, and is supported by

180B shoring panel.

A single support bracket 188 can thus be used in place of the first and second support brackets cited above 48 where a quality grade garage floor abuts the top of the foundation wall and a brick or fascia. Stone is mounted on the other side of the foundation wall.

Similar to the operation of the bracket 48, the support panels 176A, 176B transfer the weight of, for example, overlying loads of the brick or stone fascia, and the edge of the garage floor, to the wall, therefore through the base, and to the underlying natural base of eg soil or rock that supports the building. As shown in FIGURES 9A, 9B, brackets 48, and corresponding brackets 188, they may be used to support the lower parts of the floor latches or other supporting elements below the upper wall so that the upper floor 40 is in place. an elevation not higher than a height that is defined above the foundation wall a distance less than once the height of the floor structure. In the embodiment shown, the top of the floor structure is approximately at the same elevation as the top of the foundation wall. The ends of the floor support members are disposed inwardly of the outer surface of the foundation wall and into an inwardly facing surface of the foundation wall. The subfloor and finished floor, which overlaps the floor support elements, can extend beyond the floor support elements as desired. Such height leveling of eg ground floor may facilitate construction for handicap entry to the building.

Similarly, brackets 48 may be configured to support the lower parts of the floor locks at any desired elevation above the top of the wall so that the top of the floor is at any corresponding elevation relative to the top of the wall. up to a maximum height that is approximately the same as the elevation shown in FIGURE 9. Such a bracket configuration 48, 188 can thus be used to support floor locks corresponding to above-average building floors as well as Building floors that are below average. For example, where two floors of a building are below average, the brackets 48 may thus be used to support support locks on such below average floors, as well as one or more above average floors.

While supports 48 and 1888 have been described herein as being used with building panels of the invention, supports 48 and 188, when properly sized and configured, may be used with for example conventional concrete walls such as opaque walls and foundation provided that the top panel 182 is sized to fit such a conventional wall.

Turning again to FIGURE 9, the bottom plate 16, as illustrated, may be rather thin, for example, between approximately 0.45 cm and approximately 1.27 cm thick, rigid inflexible resinous pultrusion having inflection and rigidity sufficient to spread the vertical load for which the panel is projected out substantially over the full downwardly facing surface area 20 of the lower plate, thereby transferring the vertical load to, for example, the underlying aggregate stone base. .

In some embodiments, for example, a conventional concrete base 55 is interposed between the ground

2 5 natural underlying, or clean aggregate stone base, and the

bottom plate 16. In such a case, any of a wide variety of liquid deformable, crushable, adaptable, crushable, or similarly deformable gasket or connection material or other sealing material or other shape material.

The changeable, or seal with gasket or other definite but crushable bonding material such as sheet material is placed low on the base before the wall panel is placed on the base. Bonding material 51 is illustrated as a somewhat irregular thick dark line between concrete base 55 and bottom plate 16 in FIGURE 3. The wall panel is installed over the sealing material with intervention gasket or other deformable before the deformable material is cured. whereby the small cracks, spaces, between the base and the wall panel are filled with deformable material.

When the deformable material cures, the deformable material becomes a bonding, load bearing material whereby the bonding material transfers corresponding portions of the overlying load through the potentially existing spaces that have been filled with the bonding material to provide the bonding material. thus a continuous load sharing interface between the wall panel and the base along the full length of the wall panel. Such bonding material may be any material 20 sufficiently deformable to assume the contours of both the bottom surface of the plate 16 and the top surface of the base, and which is curable to create the aforementioned structural bonding configuration.

Referring again to FIGURE 9, the concrete slab floor 38 is shown overlapping that portion of the lower plate 16 extending into the building from the inner surface 57 of the wall panel 14, and inwardly from pins 123. The slab floor 38 abuts the inner surfaces of the wall panel 14 and channel pins 123, thereby stabilizing the lower end of the wall panel against inwardly directed forces reaching the lower end of the wall panel.

Although described using different nomenclature, ie wall surface and inner surface, both inner surface 57 and wall surface 25 have the same wall panel face 14 when considered long of pins 23 and 123. Contrary to surface 25, Inner surface 57 also includes the respective surface of the pin wall panel 23, 123.

Inwardly directed forces reaching the upper end of the wall panel are opposed by conventional anchorages between the overlying main floor 40 and the upper plate 20. The inwardly directed forces that are imposed on the wall panel 14 between the top of the panel and the bottom of the wall panel are transferred to the top and bottom of the wall panel, thus to the concrete floor and the overlying main floor or floor system, by the rigidity and rigidity of the wall panel. as collectively defined by the interactions of the structure defined by layers 34, 36, 50 foam blocks 32, and pins 23, 231, if used. Another reinforcement structure may be added, added to the wall, as desired in order to achieve the desired level of lateral strength and stiffness in the wall structure.

In residential construction, a normal maximum vertical load experienced by, for example, an underlying foundation wall is between approximately 44 76.25 kg per linear meter (3000 pounds per linear foot) and approximately 7460.4 kg per linear meter (5000 pounds per linear foot). The vertical crush load can be applied to the full width of the top of the wall anywhere along the length of the wall.

The moment of load of horizontal chick load

Normal maximum on such a wall is between approximately 1.52 kg per square centimeter and approximately 1.77 kg per square centimeter. The horizontal load is measured at 39 percent of the upward height from the otherwise horizontally unsupported bottom of the wall.

Referring to FIGURE 8, a normal wall panel of the invention for use in subsoil applications such as foundation walls has a nominal thickness "T" of approximately 7.62 cm. Pins 123 project approximately 8.89 cm from the inner surface 25 of the wall panel. Inner layer 34, outer layer 36, and weave layer 50 are all approximately 0.178 cm glass fiber reinforced plastic layers. Pins 123 have walls approximately 0.178 inches thick. Foam blocks 32 have densities between approximately 2.0 pcf (32.03 kg / cm3) and approximately 5 pcf (80.1 kg / cm3). Such a normal wall panel has a vertical crush strength of approximately 22378.3 kg per linear meter (15000 lb per linear foot), and a horizontal point load bending strength of at least about 2.0 kg per cm2. .

Depending on the desirably constructed safety factors within the building panels, the vertical crush strength 30 may be as small as approximately 5968.4 kg per linear meter, optionally at least approximately 8952.3 kg per linear meter, usually at least approximately 11936, 51 kg per linear meter. At least 14920.7 kg per linear meter may be specified, as may at least 17904.9 kg per linear meter.

The bending strength of the wall panel at the maximum horizontal subsoil load locus is usually at least about 1.77 kg per square centimeter, and above to about 2.5 kg per square centimeter. Both the vertical crush resistance and the horizontal point load bending moment resistance can be designed for larger or smaller magnitudes by specifying, for example and without limitation, included foam density; layer thickness 34, 36, 50; "TI" wall thickness, spacing and / or pin depth 23, 123, or "T" panel thickness, or "T" thickness in combination with structure "TI" depth.

Above average lateral loads, such as wind loads, are less than the 1.77 kg per square centimeter cited above. Consequently, the bending strengths of building panels intended for above ground applications may be less than the 1.77 kg per square centimeter cited above. Panels expected to be used in applications

Below average are designed to meet the load requirements experienced in below average applications, while panels expected to be used in above average applications are designed to meet the 30 load requirements experienced in above average applications. Such design process includes considering historical climate and / or soil movement for location of use, as well as other environmental factors. Accordingly, building panels of the invention include a wide range of panel structures and properties to provide engineering solutions that can be designed to fit the stressful environments expected to be imposed on the specific building panels to be designed. used for specific uses. One can of course also produce generic design building panels that are designed to tolerate a wide range of expected Vargas. For example, a first design specification may be made to satisfy most below-average uses while a second design specification may be made to satisfy most above-average uses.

Turning to FIGURE 1, as suggested above, conventional steel I-beams may be used in combination with wall panels 14 of the invention. As illustrated in FIGURE 1, such I-beams are supported from the underlying ground in conventional column spacing 28 that transmit I-beam loads to the underlying ground via a load diffusion shim 30. In conventional structures, The load is transmitted through a conventional steel column to an underlying concrete base chock that is poured onto the underlying ground.

In the invention, instead of a concrete base, multiple layers of reinforced polymer compound as used in the wall panel 14 are used in the manufacture of a support shim 30. Such a normal support shim 30 is illustrated in FIGURE 10, underlying a support column and supporting a structural floor support beam 26.

A cross section of a representative shim 30 on an underlying support base SB is illustrated in FIGURE 10A. As shown in FIGURE 10A, shim 30 has an upwardly facing top 3OT and a downwardly facing bottom 30B. The surface area of the underside of the shim is selected to be large enough to spread the overlying load sufficiently over the natural soil and / or the underlying rock support base that the underlying support base can support the overlying load during a period. normally indefinite period of time without harmful deformation or flow or other movement of the underlying support base. The shim is constructed of several of the normally extending fiberglass reinforced polymer composite layers 31. The layers are generally positioned such that at least a substantial portion of a relatively overlying layer overlaps a substantial portion of a relatively underlying layer, optionally including geometrically designed intercostals for strength. Normally, the layers are stacked on top of each other, optionally connected to each other at the edges 33, as when folding one layer into an upper or lower layer joining with the next, so that the respective stacking of the layers, layer upon layer, results in portions, usually

horizontally placed, which turn from their respective supporting layers, and which act collectively, thereby providing shims having sufficient bending strength to support downwardly directed loads when the shims are in use.

Such layering can be created by folding and stacking a resin-moistened fiberglass layer into a mold and closing the mold and evacuating air, thereby consolidating the shim, then curing the resin, resulting in the polymeric shim. hardened fiber reinforced. Alternatively, the fiberglass layering may be placed in the mold and in dry condition, and the resin may be added while the mold is being

evacuated.

Shim 30 is illustrated as having a normally square or round projected area, and as being used for site support such as in support of a column 28. Shim 30 may have an expanded projected area of any desired projected configuration such as for underlie and sustain multiple columns in a single area. In addition, shim 30 may have an elongate configuration whereby shim 30 may be used as a lower elongate base, and which supports any of several foundation panels 14 when such panels are used in a fabricated foundation wall.

Thus, a normal support shim may have a projected area of approximately 1 square meter to approximately 0.92 m2 when designed to support a point load such as a single column. A shim that is designed to support for example an elongated load such as a wall having a length of for example 3.05 m, 6.10 m, 12.2 m or more has an elongated dimension that corresponds in magnitude. to the length of the wall.

Shim thickness is designed to support the magnitude of the anticipated overburden. Thus, as with building panels, for each building application, shim represents an engineering solution based on anticipated loading and load distribution. The magnitude of the load as supported by shim 30 typically corresponds to the load distribution conventionally contemplated by normal single family residential construction. Accordingly, the load distribution cited herein for foundation walls may be applied such that an elongated shim can hold at least 7460.4 kg per linear meter and a square or round shim can hold loads of at least about 2.0. 0 and approximately 3.47 kg per square centimeter, more usually at least 2.50-3.47 kg per square centimeter. Higher loads may be supported by suitable engineering such as shims.

The thickness of a shim between the top 3OT and the bottom 3OB depends in part on the magnitude of charge and charge distribution, and partly on the specific resin as well as the specific structure of the reinforcing fibers and

2 5 layers of fiber as well as the nature of building the

Chock. For lightweight construction, where the shim carries a relatively lighter load, the shim thickness can be as small as 2.54 cm thick. Where the shim supports heavier loads, the shim is more

It is thick, and has the same order of magnitude of thickness that it could have been used if the material were steel reinforced concrete. As such, the shim thickness typically ranges from approximately 7.62 cm in thickness to approximately 4.64 cm in thickness, optionally approximately 15.24 cm in thickness and approximately 40.64 cm in thickness, optionally between 20.32 cm in thickness. thick and approximately 40.64 cm thick, with all thicknesses between 2.54 cm and 4.04 cm being contemplated. Thicknesses less than 7.62 cm and greater than 4.04 cm are contemplated where anticipated vertical loading and load distribution, together with material properties, indicate such thicknesses.

In general, the thickness dimension is smaller than the length or width dimension. As illustrated for example, in FIGURE 1, typically the magnitude of the thickness dimensions is not as large as half the magnitude of the lower length dimension or

width.

In any event, the structure shown in FIGURE 10A is not limiting as for the layer structure. For example, the fiberglass layers may be configured as an elongate roll where relatively outer layers are wrapped around one or more core layers or relatively inner ones.

Alternatively, as illustrated in FIGURE 10B, shim 30 may be a pultruded fiberglass reinforced polymeric structure such as a solid pultruded plate or a rectangular tube positioned such that the cavity 37 extends horizontally through the structure. Such rectangular tube has a normally horizontal inner or upper web 34, a normally horizontal outer or lower web 36, and one or more normally straight connecting webs 35 which support the upper web from the bottom web. In the embodiment illustrated in FIGURE 10B, cavity 37 is hollow. In other embodiments, a honeycomb or other weft structure extends the length of the cavity 37, thereby providing connecting structure between the upper weft 34 and the lower weft 36, which can provide structural support that supports the upper weft from the weft. by which it assumes some of the weft support function or connecting frames 35.

Column 28 is generally depicted in FIGURE 1. Although column 28 may be of steel, and shim 30 may be of concrete where wall panels of the invention are used, the invention contemplates that column 28 may be a steel structure. hollow fiberglass reinforced polymer composite. Resin curing as on shim and construction panels can be used to assemble and bond column 28 to shim with conventional shim placement

as desired.

Such a resin-fiber composite column 28 has a

usually closing structural sidewall. The column sidewall is made of fiberglass reinforced polymer composite or other fiber reinforced resinous structure. The thickness and stiffness of the column sidewall is designed as known in the art to carry a specified load, to thereby support the weight of an overlying portion of a normally above average structure, although below average structures may also be supported. The closing column sidewall defines an inner chamber disposed into the closing sidewall. The inner chamber is normally empty, but may contain structural or nonstructural material as desired.

Where the fiberglass column 28 is used, a cover of fiberglass reinforced polymer compound 58 is usually mounted on top of the column. The lid 58 has an upper wall 60, and one or more downwardly dependent structural edges 62. The upper wall 60 of the lid is sufficiently thick and rigid to receive the load from the overhanging beam and to transmit the load generally evenly around the perimeter. that of the outer walls straight from the column, including where the outer walls may be laid laterally outwardly from the edges of the beam. The structural edge (s) are configured such that when the cover is mounted on the column, with the upper wall of the cover resting down over the top of the column, the inner surface of the border or edges is generally in surface-to-surface contact. with or in proximity to the external surface of the column, so that the edge structure receives and absorbs commonly encountered lateral forces and transfers such lateral forces to the column sidewall, thereby preventing the top of the lid from moving laterally relative to

upper part of the spine.

Lid distributes side loads to walls

column sides and with limited folding of the top wall of the cap so as to substantially utilize the load-bearing capacity of the column side walls from or near the top edge of the column along the full column height to underlying shim 30. The cap edges thus capture lateral forces and transfer such lateral forces to the column.

An alternative to cap 58 is to use a conventional adjustable screw 59 over the top of the column 28. Such a bolt 59 may be used in place of cap 58, or in combination with cap 58, for example between cap 58 and the overlying beam 26. Where both cover 58 and screw 58 have been used, a suitable screw / cover interface is configured on the screw and / or cover to ensure proper cooperation of the cover and

screw with respect to each other.

FIGURE 11 illustrates a polymer composite shim

square fiberglass reinforced polymer 30 of the invention, a square fiberglass reinforced polymer composite column 26 of the invention, and a square fiberglass reinforced polymer composite cap 58 of the invention. FIGURE 12 illustrates a shim / column / cap combination similar to that of FIGURE 11 but where the shim is tapered from the top of a shim base upward to where the shim meets the column. FIGURE 13 illustrates a shim / column / cap combination similar to that of FIGURE 11 but where the column, shim, and cap are circular. FIGURE 14 illustrates a shim / column / cap combination similar to that of FIGURE 13 but where the shim is tapered from the top of a shim base upward to where the shim meets the column.

Although the shim / column / lid combinations shown in FIGURES 11-14 may be used within the building as in a foundation column arrangement as suggested in FIGURE 1, a primary purpose of the invention is to avoid the need to bring a site-ready mixing concrete truck, is advanced by utilizing shim / column / lid combinations such as those illustrated in FIGURES 11-14 in off-foundation applications such as to support a deck, a porch, a patio, a light column, or other attachment. In such an application, the shim and spine are placed on the ground below the opaque line. The spine is then cut normally, but not necessarily below average. The conventional structure such as a 4x4 treated wood column is then mounted on the upper part of the lid 58, and the lid is subsequently mounted, for example, adhesively mounted, on the upper part of the column. With, for example, the 4x4 column thus extending upwards, with the lid for example permanently adhesively mounted to the column, the hole is filled to the grid so that only the conventionally used wooden column remains visible. Thus, normal external attachments for construction can be contemplated, again without any need to bring ready mix concrete, or concrete block, to the construction site. This can provide a significant time and cost advantage when only a small amount of concrete on the other would be needed as the truck cost is fixed even for a small amount.

amount of ready mix concrete.

In other embodiments, the fiberglass column 28 may extend above average, and may support a wide variety of suitable overlying structures.

As indicated above, it is an object of the invention to use wall panels and fitting structure in places, and for structural purposes, where concrete would be conventionally used. The use of concrete in foundation walls is common, and the products of the invention are readily adapted for use in foundation structures.

However, especially in more tropical climates, above-average external walls are required to be, in some cases, constructed of concrete in order to, among other advantages, inhibit mold growth. Where high wind conditions such as hurricanes or tornadoes are common, above average outer walls are required to be in some cases constructed of concrete in order to achieve the additional lateral resistance that can

withstand such wind forces.

In such situations, such as in hurricane or tornado-frequented areas, above-average wall structures of the invention may be used in place of concrete, while achieving concrete lateral load bearing properties and for example preventing water penetration, and other innate limitations in concrete. Accordingly, the wall structures of the invention are contemplated to be useful in above ground applications as well as below ground / foundation wall applications. The fiber

The reinforcing fiber materials used in products of the invention may be selected from a wide variety of conventionally available fiber products. Fiberglass has been illustrated in the general description of the invention, and is believed to be the most cost effective material. Other fibers that are contemplated as being acceptable include, without limitation, carbon fibers, Kevlar fibers, and metal fibers such as copper and aluminum. Other fibers may be selected to the extent that their reinforcing properties and other properties satisfy the structural demands of the building panel applications contemplated by the invention, and provided that the fibers are not prematurely degraded in the intended use environment for the respective wall panels. .

For that purpose, the use of cellulosic fibers is limited to those compositions wherein the cellulosic fiber can be adequately protected from the damaging and degrading effect of moisture reaching the fiber. Thus, the use of cellulose fiber without moisture protection is not contemplated as part of the invention, except in amounts less than percent by weight of the overall composition of a given structural element, e.g. panel, support, or the like. However, where the fiber is impregnated with an adequate amount of resin, the resin protects the cellulosic fiber from moisture attack, and thus such compositions.

of compound can be used.

Fiber lengths, widths, and cross-sectional shapes are selectable according to the structural demands of the structures in which building panels or other structures are to be used.

Braided fiber-based sheets, such as braided fiberglass cloth, are contemplated to be efficiently layered for use in building panels of the invention. However, those skilled in the art will recognize that a wide variety of processes, and corresponding forms of handling and processing fibers, as well as resin, are available to produce the building panels of the invention. The selection of fiber structures may be specified to accommodate all such processes, whereby all fibers that may be employed in all such processes, for example cut, mat, or braided fibrous material, to achieve structural, insulating, and other desired properties normally desired in a foundation wall, or an above average wall, may be used in building panels and other elements of the

invention.

Reinforcement fibers are generally known as dry fibers or prepregs for the purpose of the fiber reinforced resin manufacturing process. The fibers contemplated for use herein are usually dry fibers, although some wet fiber processes are contemplated as being useful in producing products of the invention. 0 Polymer

The polymer that is used to impregnate and / or transport the fiber may be selected from a wide variety of conventionally available multi-part cure reaction resin compositions. Normal resin is a 2 part liquid where two liquid parts are mixed together before the resin is applied to the fiber substrate. Additional third components may be used in the reaction mixture as desired in order to achieve the desired level of resin reaction cure. The resin mixture would be sufficiently liquid to be readily applied and spread around a fiber base / substrate to thereby fill in all voids in the substrate. Examples of useful two-part reaction curing resins include, without limitation, epoxy resins, vinylester resins, polyester resins, polyurethane resins, and phenolic resins. Those skilled in the art know that each of the above resins represents a large family of reagent materials that can be used to produce the resulting reaction cured resin, and are capable of selecting reaction resin combinations for the uses contemplated by the invention. In addition, more than two of such resins may be mixed to obtain a desired set of properties in the reaction product or process.

For any set of reaction materials that are used to produce the resins illustrated herein, any conventional additive package may be included such as, for example and without limitation, catalysts, antioxidants, UV inhibitors,

fire retardants, and flow control agents, to achieve the process of resin application and / or resin cure, and / or to achieve the properties of the finished product, eg weather resistance,

to fire, hardening, and the like.

Each set of two or more materials that can be mixed and reacted to produce the resulting resin product has its own reaction parameters, including desired reaction temperature, catalysts, time required for the curing reaction to act, and the like. In addition, each set of such two or more materials develops its own resulting set of physical and chemical properties as a result of the curing process. Especially the physical properties are influenced by the effect of the included fibers, so that more than two reagents may be useful for achieving a desired set of physical properties in the reacted polymer. Polymer / Fiber Compound

In general, dry fiber substrate, braided cloth, or fiber mat are used as the fiber base for all structural layers such as layers 34, 36, 50; as well as for all other structural elements of the invention such as columns, 28, shims 30, covers 58, channel pins 123, and brackets 48, 140, 148, 150, 160, 170, and 188. Since the purpose is fill substantially all voids in the fiber substrate with resin, sufficient resin is added to the fiber substrate to fill all such voids, so there should be no air inclusions, or so few air inclusions so as to have no material effect. on the physical or chemical stability, or physical properties, of a building panel or other structure constructed of such a resin-impregnated fiber-based layer. Overall, the glass / resin ratio is as high as can be achieved, and leaving no meaning, noxious voids in the resulting layer once the resin is cured.

Alternatively, layers 34, 36, 50 may be fabricated using pre-impregnated fiberglass layers, i.e. fiberglass substrates which were resin impregnated before being fabricated into a structural element preform, and which They can be cured by, for example, applying heat as in a curing oven.

Given the requirement to minimize vacuums, and using conventional layer development techniques, the resulting structural layer product, for example layers 34, 36, 50, or other products, is from about 30 weight percent to about 65 weight percent. percent by weight of fiberglass, and therefore between about 70 percent by weight and about 35 percent by weight of resin. Optionally, the resulting layer has from about 40 weight percent to about 60 weight percent fiber and from about 60 weight percent to about 40 weight percent resin. A normal resulting layer has from about 45 weight percent to about 55 weight percent of fiberglass and from about 55 weight percent to about 45 weight percent resin, optionally about 50 weight percent fiber. glass and about 50 percent

resin weight.

According to well-known technology, the number of

Glass layers, in combination with the weight of glass per layer, generally determine the thickness of the resulting layer after the resin-impregnated layer is cured. For example, multiple layers of one layer of 10332.68-10332.85 kg per square meter (12-17 ounce per square yard) of braided fiberglass cloth may be

impregnated to fill all the vacuums, and thereby achieve a resulting cured structure which is usually about 1 millimeter thick to about 2.5 millimeters thick. The greater the number of fiberglass layers that are impregnated, usually the greater the thickness of the resulting reinforced and impregnated composite reinforced layer.

The bottom and top plates as well as layers 34, 36, and 50 may be made of such polymer / fiber compound. The lower plate may be any material that can withstand the load imposed on the overlying wall panel. A normal lower plate has, for example, a fiber-reinforced pultrusion between about 0.45 cm thick and about 1.27 cm thick, which is sufficiently inflexible and rigid to spread the charge above the generally uniformly underlying soil substrate. along the length of the panel through for example a flush clean aggregate stone base. The stone may be a crushed stone or an uncrushed aggregate stone.

The top plate 20 may be made of, without limitation, resinous, fiberglass reinforced materials, or other fiber reinforced materials, or other materials such as wood, in the shape conventionally used for a top plate. It is contemplated that a conventional wood-based top plate will serve the purpose properly, and provide attachment of overlying wood elements such as wood framing, which use conventional fasteners and conventional adjustment methods. The foam

The purpose of the foam, as in foam blocks 32, is generally two-fold. First, the foam contributes to the structural integrity of the building panel structure by being sufficiently rigid, i.e. a rigid foam, that the foam significantly contributes to securing the structural layers 34, 36, and 50 in their projected positions under normal loading. panel, both vertical gravitational loading and lateral loading such as lateral ground loads in below average applications and lateral wind and / or water loads in above average applications. As such, the foam makes a substantial contribution to

dimensional stability of panel 14.

Second, the foam provides substantial thermal insulation to the resulting building panel construction.

By achieving a desired level of thermal insulation while retaining the foam as a rigid closed cell material, the foam has a density between approximately 16.01 kg per cubic meter (kg / m3) and approximately 192.2 kg / m3, optionally between 32.02 kg / m3 and approximately 128.1 kg / m3, optionally between approximately 32.02 kg / m3 and approximately 8 0.1 kg / m3. Lighter weight foams generally do not provide sufficient rigidity to hold the foam hole in securing the structural layers to their designed locations and such lighter weight foams may be open cell foams. Although heavier foams may be used, and usually provide more structural strength, such heavier foams provide less than the desired level of thermal insulation properties, and are more expensive. In general, the foams used in the invention are closed cell foams.

Foam blocks 32 may be made from a wide variety of compositions including, without limitation, extruded polystyrene foam, expanded bead polystyrene foam, urethane foam, or polyisocyanide foam. The foam is moisture resistant, preferably moisture proof, and is chemically and physically compatible with the compositions and structures of layers 34, 36, and 50.

With respect to securing the respective structural layers in their projected positions, the foam fills all, or substantially all, of the spaces between the respective surfaces of the structural layers 34, 36, and 50, and is in surface-to-surface contact with the respective layers as Such layers define the cavities in which the foam is received. In addition, the foam is adhered to the respective structural layers to absorb biasing forces between the foam and the respective structural layers.

The foam blocks 32 may be placed surface to surface with one or more of the structural layers 34, 36, 50 after the resin has been applied to the respective fiber substrate that is used to form the layers and before the resin is cured, whereby the respective one or more surfaces of the foam blocks, which are in surface to surface contact with the respective resin coated fiber substrate, become moistened with the uncured resin. With the foam in contact with the fiber reinforced layer to be cured, and moistened by the fiber reinforced layer, the resin cure binds the foam blocks to the structural layers 34, 36, 50 as it applies, so no adhesive. A separate layer is necessarily required to bond the foam blocks to the structural layers.

Throughout this teaching, reference has been made to the fixing of various elements of the building panels together. In some cases, mechanical fittings such as bolts have been mentioned, such as for securing the upper plate to the support 24. In cases where two elements are fixed together, and where both elements contain resin components, especially reaction cured components. Curing the resin on either of these two structural elements being formed or joined can be used to secure the elements together so that no adhesive is required. On the other hand, where components are assembled together at the construction site, at least in some cases, the use of e.g. conventional adhesives and sealants which are known for utility in construction projects is contemplated.

An example of using building adhesive when joining the foundation wall is to secure the bottom plate to a wall panel 14. Wall panels 14 can be transported to the construction site without the top plate or bottom plate, and where materials Top plate and bottom plate materials can be transported to the construction site separately, although potentially in the same vehicle. Bottom plates and top plates are then fixed to the wall panels at the construction site as desired. The bottom plate is normally fixed to the bottom of the wall panel with a construction adhesive, with or without the assistance of brackets 24. The top plate can be fixed to the top of the wall panel using brackets 24 and bolts 139, and / or other supports as required, and optionally further adhesive between the top plate and the top of the wall panel.

Brackets 48, 140, 150, 160, and 170 may be

adhesively mounted on the building panels. Alternatively, the surfaces of the respective parts, including the respective areas of the building panels, may be coated with a cure resin supply.

before the parts are assembled, and the parts can then be held together for a sufficient time under satisfactory conditions that result in the cure of the resin, whereby the cure of the resin develops the desired level of attachment between the respective parts of the wall.

2 0 Similarly, both adhesively and by use of

Curable resin materials, channel pins 123, support brackets 24, 48, and floor and garage bulkhead brackets 18 8 may be mounted to a wall panel after the wall panel has reached the construction site.

2 5 It is understood that any bracket attachment 24 to the

The inner surface of the wall panel should generally be fully developed so that its required operating resistance before the top plate or bottom plate, as applied, can be fixed to the wall panel and

3 0 apply your taxed charge to bracket 24. EXAMPLE

In general, wall structures of the invention may be engineered to support any level of compressive load that is contemplated to be applied to the construction. For example, and without limitation, using conventional braided fiberglass substrate, a demonstrative foundation building panel, such as the panel illustrated in cross section in FIGURE 8, may be constructed generally as follows, and having a bearing capacity projected compressive load of approximately 22381.2 kg per linear meter of the wall panel.

Braided fiberglass is used for the base, for example substrate of structural layers 34, 36, and 50, as well as for the channel pin base substrate 123. The fiberglass substrate may be braided fiber substrate. three axles having a basis weight of approximately 10333.02 kg per square meter. Another exemplary fiberglass substrate is a b-uniax braided fiber substrate having a basis weight between approximately 103,326 kg per square meter and approximately 103,332 kg per square meter. Yet another example on a braided cardboard that has a base weight of approximately 10,332.85 kg per square meter. The selected fiberglass substrate, for example,

For example, a 0.623 kg braided substrate is placed outside on a horizontally disposed release material such as a MYLAR® oriented nylon layer. Other materials may be replaced by the release sheet and become part of the finished wall panel while achieving processing line separation as well as to achieve a desired exterior finish on the wall panel. The fiberglass substrate is swept or otherwise impregnated with a sufficiently curable two-part epoxy resin and in such a process to substantially fill all voids in the braided fiber substrate to thereby create a first preform. to outer layer 36 to the wall structure, and where the thus prepared preform is moistened with epoxy resin which substantially fills all voids in the fiberglass substrate.

Several blocks of closed cell foam, approximately 7.62 cm thick, 2.32 cm wide, and extending to the full height of the laying layer 36, are placed on the laying layer 36, parallel to each other. , and spaced locations along the length of the panel. As used herein, the height, length, and thickness of a wall panel refers to the panel in its orientation of

20 vertical use in for example a foundation wall

vertical or above average wall. "Width" refers to such a height dimension of the building while the building is being fabricated in the horizontal orientation noted above. As the foam blocks are placed over the horizontal preform of the first layer, some of the weft resin over the first layer preform transfers to the dry foam blocks. Alternatively, one or more surfaces of the foam blocks may be pre-moistened with a desired amount of foam.

3 0 curable resin. In any event, the foam blocks on the wet preform support a certain level of surface liquid in the form of curable resin.

A second wet-woven layer preform moistened with the same two-part epoxy resin is prepared in the same manner as the first outer layer, and is woven back and forth over the outer layer preform combination. and the foam blocks 32, with the moistened weave layer weaving back and forth in face to face contact with the blocks and the

layer preform 36 along the complete overall surface of the respective construction, leaving elongated voids in the construction between the respective blocks.

A second set of several foam blocks 32, optionally pre-moistened with epoxy resin, is in

It is then inserted into the voids between the foam blocks already in the structure, thereby filling the entire length and width of the layer preform 36. Consequently, the combination of foam blocks 32 and the weave layer preform 50 has a surface

2 0 continuous and generally uniformly superior top of the

resulting construction at this stage of assembling the building panel, and all blocks, layer preform 36, and layer preform 50, are wetted with epoxy resin.

A third moistened inner layer preform 34

is prepared in the same manner as the first outer layer preform and the weave layer preform, and is placed on top of, and pressed over, the construction, so that the third layer preform

30 serves as a coating layer covering the entire upper surface of the resulting construction. At this stage, the foam blocks are propelled towards each other to consolidate the foam blocks and the weave layer together.

Channel pins 123 can be pressed to

inside, and about building at that time from and as desired. The channel pin tabs 126 may be pre-coated with epoxy resin, or may simply be pressed into the moistened surface of the layer preform 34. In general, members 128 and end panels 130 of the post pins channel remain dry, and are not coated with epoxy resin. A loading bar, loading belt, or other loading structure may optionally be applied through the upper portions of the channel pins to the end panels 130, pressing the channel pins into the inner layer 34, and thereby applying a load. generally tending to consolidate the building panel from top to bottom, including channel pins 123, layer preform 34, foam blocks 32, weave layer preform 50, and outer layer preform 36

The construction is maintained in the condition thus assembled and consolidated while the resin cures sufficiently to permanently fix the respective elements in the panel construction in their respective locations, thereby forming the resulting construction panel 14.

In the resulting panel, 0.623 kg epoxy resin impregnated fiberglass layers develop cured fiber reinforced polymeric layers that are approximately 0.9 mm thick. FIGURE 25 illustrates such an exemplary non-limiting wet layering method by which building panels 14 of the invention may be made in a continuous process, and whereby the building panels thus manufactured may be cut to any desired length at the end of the panel. manufacturing process. As seen in FIGURE 25, a first unwind unwinds a roll 64 of a conveyor web 66, for example, a layer of MYLAR®, and feeds the conveyor web to a processing line 68. The conveyor web traverses the processing line, carrying several workpieces along the processing line as the building panel is fabricated and hardened. The conveyor web 66 is separated from the cured workpieces, work product, at a point after the construction panel product thus manufactured has cured sufficiently to be dimensionally stable. After the conveyor web is separated from the cured workpieces, the conveyor web is wound over a roll winding 70.

A first layer of fiberglass substrate 72 is unrolled from a roll of such material and is fed generally downwardly through a pair of bit rollers 74 carrying a two-part curable resin hydraulic cement 76 and applying such resin to the substrate 72, and squeezes such a resin into the substrate 72 as the substrate passes through the defined bit between rollers 74, to thereby develop a progressively resin-impregnated outer layer preform 36. The moistened preform is conveyed through one or more guide rollers down and over conveyor web 66, and where the conveyor web and progressively impregnated outer layer preform 36 are moving at approximately the same speed along the processing line. 68

Still referring to FIGURE 25, a first foam block stack 86A 32 provides a supply of foam blocks. The foam blocks are placed on the outer layer preform 36 at spaced locations. The foam blocks extend the full width of the outer layer preform 36. The blocks as illustrated are 20.32 cm wide and are spaced approximately 20.32 cm apart by voids 84 on the preform. layer 36. Foam blocks 32 may or may not be pre-moistened with curable resin as desired.

A second layer of fiberglass substrate 78 is unrolled from a roll of such substrate material and is fed vertically downwardly through a pair of bit rolls 80 carrying a two-part curable resin hydraulic cement 82-20. , and apply such resin to substrate 78, and squeeze such resin into substrate 78, as the substrate passes through the defined roll-over bit 80, to thereby develop a resin-moistened weave layer preform 50. THE

2 5 moist preform is transported through one or more

guide rollers down and over the outer layer preform 36 and blocks 32, and where the weave layer preform, as it approaches the construction on the conveyor web, is moving at a speed

30 which is faster than the travel speed of outer layer 36 and foam blocks 32, and which is consistent with weave and weave layer within the entire upper surface of the building, including the upper surface of the building. outer layer preform 36, the upper block surfaces 32, and the block side surfaces 32 extending away from and toward the outer layer preform 36.

The outer layer preform thus remains in close contact with all previously exposed surfaces of the underlying construction. The resulting construction has no substantial vacuum, no substantial air pockets between the weave layer and the outer layer preform 36, or between the weave layer and the foam blocks, which cannot be subsequently eliminated in the process. The weave layer then forms the entire upper surface of the resulting intermediate construction. The resulting intermediate construct defines channels extending along the width of the construct as viewed on the paper in FIGURE 25. Reaffirmed, voids 84 between foam blocks 32 on the left side of FIGURE 25 remain vacuums; while the vacuums were aligned with the weave layer preform 50.

2 5 The voids 84 are then filled with blocks of

additional foams 32 from a second stack 86B of such foam blocks. The foam blocks may or may not be pre-moistened with curable resin as desired. After the blocks were in place, voids 84 were

30 completely filled by the foam blocks, resulting in a generally flat, continuous surface as shown in FIGURE 25 to the right of the second stack of foam blocks 86B.

A third layer of fiberglass substrate 88 is uncoiled from a roll of such material and is fed generally downwardly through a pair of bit rolls 90 carrying a two-part curable resin hydraulic cement 92, and applying such resin to the substrate 88, and squeezes such a resin into the substrate 88, as the substrate passes through the defined bit between rollers 90, to thereby develop a resin moistened inner layer preform 34. The moistened preform is conveyed through one or more guide rollers down and over the upper surface of the underlying resin wetted construction, and where the inner layer preform 34 and the underlying construction, as carried by the conveyor web 66, are displaced. at approximately the same speed along processing line 68.

After the inner layer preform 34 has been applied to the building, the resin moistened inner layer preform covers the entire width of the upper surface of the building. Channel pins 123 are optionally applied to the building, along the width of the building, at locations spaced along the length of the building, consistent with the desired spacing of the pins in the finished building panels.

As desired, an overload or other downwardly directed force may be applied to the channel pins to assist the channel pins in becoming wetted with the resin that is contained in the inner layer preform 34, and to propel the pins. for close agglutination contact with inner layer preform 34. Such a load may be applied to each channel pin by a distinct loading structure for each pin. Alternatively, a loading structure such as a plate or belt may be applied to multiple pins, thereby connecting the spaces between the respective pins. Such a loading structure may take the form, for example and without limitation, of a loading belt. As desired, the charge may be applied to the entire surface of the building to further propel into remaining voids. As a result of loading, the number and size of any remaining vacuums are sufficiently reduced so that any remaining vacuums are of little or no consequence to the overall construction strength.

Alternatively, or in addition, more resin may be applied to the lower surfaces of the channel pin tabs 126, to thereby facilitate wetting contact between the pin tabs and the inner layer preform.

Once the inner layer preform is applied to the construction, with the channel pins applied according to design, if the pins are used, the construction thus formed is passed through a curing furnace 94 or other process. cures as needed to thereby cure the curable resin. As the resin cures, it settles, also known as hardening. The chemical concept is that the reactionable portions in the curable resin components react to form long chain polymers, with a substantial increase in molecular weight, which results in the reaction materials being transformed from a liquid form into a liquid. It is known generically as a solid plastic; thereby generally fixing the dimensions of the reaction products so that the reaction products are dimensionally stable, and render the resulting panel into rigid and rigid fiber reinforced product that is desired for building panels 14.

As the hardened, reacted construction emerges from the curing process, the construction / product is sufficiently rigid, inflexible, durable,

is dimensionally stable so as to have no need for conveyor web 66, whereby conveyor web 66 is removed from the construction / product and wound on the take-up roll 70.

An additional layer may be added between the conveyed web 66 and the outer layer 36, for example as an appearance layer to enhance the appearance of the outer surface of the resulting building panel. Such a layer could be added for example as a gel coating or as a preformed layer. As a preformed layer, such a layer could be used in place of the conveyor web 66; such an additional layer becoming part of the building panel product thus manufactured. In such a case, the additional layer is installed on unwinding roll 64 instead of MYLAR material, and winding 70 is no longer required. Alternatively, or in addition to FIGURE 25, a gel coating layer or other appearance layer could be added over the top of the inner layer 34, optionally over the top of the studs 123, to provide a desired appearance on the inner surface of the finished building panel 14.

The product made according to the process illustrated in FIGURE 25 may be a continuous length product. Edge trim saws 96 over opposite edges of processing line 68 trim the edges of the building to obtain a desired width resulting from the building. A cutting saw 98 extends transversely through the processing line. The saw 98 is used to periodically produce a cross section through the construction thus produced to thereby cut construction panels from continuously produced construction to desired lengths.

Still reflecting on the machines and processes illustrated and described with respect to FIGURES 8 and 25, another embodiment of building panels of the invention is illustrated in FIGURE 26, and an exemplary process for producing such a building panel is illustrated in FIGURE 27.

Turning now to FIGURE 26, the outer layer 36, the weave layer 50, and foam blocks 32 are the same materials, same structures, and the same relative positioning as FIGURE 8. The main difference between the embodiment of FIGURE 8 and the embodiment of FIGURE 26 is that pins 123 are positioned between the weave layer 50, at remote locations from the outer layer 36, and the inner layer 34. In such structures, the pins 123 are held together by entrapment of the webs. pins 123 between the weave layer 50 and the inner layer 34. Any adhesion between the pins 123 and the weave layer can operate to further maintain and secure the position of the pins 123 in the assembly. The location of the pins 123 is illustrated in FIGURE 26 as being in the weave layer 50 such that the weave layer is between a foam block and the inner layer.

FIGURE 27 illustrates a method by which panels of

Construction 14 as shown in FIGURE 26 may be made in a continuous process similar to the process illustrated in FIGURE 25. As seen in FIGURE 27, a first unwind unwinds a roll 64 of a web.

conveyor 66, for example a layer of MYLAR®, and feeds the conveyor web to processing line 68. The conveyor web traverses the processing line, carrying several workpieces along the processing line as the panel

The construction is fabricated and hardened, and is separated from the cured workpieces, work product, at a point after the construction panel product thus manufactured has cured sufficiently to be dimensionally stable. After the conveyor web is separated, it makes pieces of

2 5 cured work, the conveyor web is wrapped over

a winding roll 70.

A first layer of fiberglass substrate 72 is unrolled from a roll of such material and is generally fed down through a pair of bit rolls.

304 carrying a two-part curable resin hydraulic cement 76, and applying such resin to substrate 72, and squeezing such resin into substrate 72 as the substrate passes through the defined bit between rollers 74 to develop thus a progressively resin-impregnated outer layer preform 36. The wetted preform is conveyed through one or more guide rollers down and over the conveyor web 66, and where the conveyor web and preform web are formed. progressively impregnated outer layer 36 are moving at approximately the same speed along processing line 68.

Still referring to FIGURE 27, a first foam block stack 86A 32 provides a supply of foam blocks. The foam blocks are placed on the outer layer preform 36 at spaced locations. The foam blocks extend the full width of the outer layer preform 36. The blocks as shown are 20.32 cm wide and are spaced approximately 2.32 cm apart over the layer preform 36, with voids 84 between the respective blocks. Foam blocks 32 may or may not be pre-moistened with curable resin as desired.

A second layer of fiberglass substrate 78 is unrolled from a roll of such substrate material and is fed vertically down through a pair of bit rolls 80 carrying a two-part curable resin hydraulic cement 82, and applies such resin to substrate 78, and squeezes such resin into substrate 78 as the substrate passes through the defined bit between rollers 80 to thereby develop a resin-moistened weave layer preform 50. The wetted form is carried through one or more guide rollers down and over the outer layer preform 36 and blocks 32, and where the weave layer preform, as it approaches the construction on the conveyor web, is moving at a speed that is faster than the speed of displacement of outer layer 36 and foam blocks 32, and which is consistent with weaving and weaving layer into the entire of the upper surface of the building, including the upper surface of the outer layer preform 36, the upper block surfaces 32, and the block side surfaces 32 extending away from and toward the outer layer preform 36

The outer layer preform thus remains in close contact with all previously exposed surfaces of the underlying construction. The resulting construction has no substantial vacuum, no substantial air pockets between the weave layer and the outer layer preform 36, or between the weave layer and the foam blocks, which cannot be subsequently eliminated in the process. The weave layer then forms the entire upper surface of the resulting intermediate construction. The resulting intermediate construct defines channels extending along the width of the construct as viewed on the paper in FIGURE 25. Restated, voids 84 between foam blocks 32 on the left side of FIGURE 25 remain vacuums; while the vacuums were aligned with the weave layer preform 50.

The vacuums 84 are then filled with additional foam blocks 32 from a second stack 86B of such foam blocks. The foam blocks may or may not be pre-moistened with curable resin as desired. After the blocks were in place, voids 84 were completely filled by the foam blocks, resulting in a generally flat, continuous surface as shown in FIGURE 27 to the right of the second stack of foam blocks 86B. At this stage, the foam blocks are propelled towards each other to consolidate the foam blocks and the weave layer together.

Channel pins 123 are then applied to the building, along the width of the building, at locations spaced along the length of the building, consistent with the desired spacing of the pins between each other in the finished building panels. In the embodiment illustrated in FIGURE 26, pins 123 are positioned on the weave layer 50 at locations where the weave layer is remote from the outer layer 36.

A third layer of fiberglass substrate 88 is unrolled from a roll of such material and is fed generally downwardly through a pair of bit rollers 90 carrying a two-part curable resin hydraulic cement 92, and applying such. resin to substrate 88, and squeeze such resin into substrate 88 as the substrate passes through the defined bit between rollers 90 to thereby develop a resin-moistened inner layer preform 34. The moistened preform It is conveyed through one or more guide rollers downwards and over the upper surface of the underlying resin moistened construction. The velocity of layer 34 is accelerated relative to the velocity of displacement of the underlying construction, whereby layer 34 is applied over pins 123 so that the full strength of layer 34, when cured, keeps the pins in their projected locations in the wall structure. finished.

After the inner layer preform 34 has been applied to the building, the resin moistened inner layer preform covers the entire width of the upper surface of the building including covering pins 123.

By positioning pins 123 over those portions of the weave layer that are remote from the outer layer 36, the weave layer and the inner layer reinforce adjacent pins 123, whereby the coordinate locations of the weave layer, the inner layer, and the pins provide cumulative and cooperative resistances / bending forces for external forces that are directed into the building.

Since the inner layer is cured as in curing station 94, the configuration of the inner layer adjacent the pins 123 permanently generally assumes the pin configuration table. Consequently, the

The strength characteristics dictated above for pins 123 are much less important in embodiments represented by FIGURE 27, whereby the structure and / or materials from whose pins 123 are made can still, but need not, provide substantial structural strength to the building panel. Instead, such strength is available from the inner layer 34. In such structures, pins 123 may be made from, for example and without limitation, foam polystyrene blocks, polyurethane, or other foam polymer, or another relatively low cost material to choose from, provided that the structural strength of the pins is sufficient to support the desired structure and smooth the inner layer 34 in its preform state and until such time that the inner layer 34 has been cured.

Another embodiment of the building panels of the invention is illustrated in FIGURE 28. In the embodiment of FIGURE 28, each foam block 32 is wrapped in one or more resin impregnated fiberglass layers 190 which closely and intimately surrounds the outer surfaces. longitudinally extending blocks, optionally all longitudinally extending external surfaces of the block.

The resin can be added to the fiber layers of

2 0 glass wrapped on one or more sides of the foam blocks

before the foam blocks are introduced into the process of assembling building panels of the invention. Such pre-added resin in the wrapped fiberglass layers can be cured prior to joining the foam blocks in a panel. Alternatively, the resin may be cured later, along with curing the resin in the inner and outer layers.

Alternatively, all of the resin used to consolidate the wrapping layers and bond the

30 Foam-wrapping layers may be added to, dispersed in, fiberglass layers of the foam blocks after the foam blocks have been joined with some or all of the remaining elements of the panel structure.

Fiberglass in a wrapping layer may be applied as a winding of overlying fiber strands in a pattern extending along the length of a given foam block. Alternatively, the fiberglass may be a pre-braided fiberglass mat which is wrapped around the foam block to form for example a back joint or an overlying joint where the ends of the wrapping layer meet.

Whether the wrapping layer is applied as a wrap of overlying yarns or as a braided fabric, the wrapping layer can represent an open pattern where some of the foam surface is exposed to casual visual observation through openings in the wrapped pattern. Alternatively, the wrapping layer may represent a closed pattern where the fiberglass yarns visually obscure substantially the entire underlying surface of the foam block.

Given the presence of the wrapping layers, the weave layer 50 is not used.

An exemplary process for producing building panels of FIGURE 28 is, for example, a vacuum infusion process, illustrated in FIGURE 29. In FIGURE 29, the upper and lower layers of the vacuum pouch are illustrated as 192A and 192B respectively, and where The bag is still open to gather the elements of the structure being manufactured. As suggested in FIGURE 29, one or more fiberglass preform layers, which will become the outer layer 36, are placed out over the lower layer 192B of the vacuum pouch. Thereafter the foam blocks 32, pre-wrapped in layers 90, are placed side by side on the outer layer preform. Then, and optionally, preformed and cured pins 123 are added to the top of the wrapped foam blocks. One or more fiberglass preform layers, which will become the inner layer 34, are placed over the top of the resulting subgroup, along with any desired resin distribution layer. The vacuum pouch is then closed, the vacuum is extracted and the resin is admitted into the pouch, whereby the resin penetrates vacuums into the fiberglass layers, and the vacuums between the layered surfaces 190, and is cured in the vacuum pouch. according to conventional vacuum infusion practice of filling resin into the bag and curing such resin in the bag; whereby layers 34 and 36, enclosed blocks 32, and pins 123 are all joined together as a unitary 20 composite structure.

In some cases, the wrap layers 190 are not filled with resin prior to the vacuum infusion process, whereby the resin that enters the bag during vacuum infusion processing fills the voids in the wrap layers as well as the voids in the preforms. 34 and 36. In other cases, the wrapping layers 190 have already been filled with resin. In some cases, the resin has been cured, in which case the resin introduced in the vacuum infusion process serves to adhere the respective blocks involved together as well as to permeate the inner and outer layer preforms thereby consolidating all the components. in a unitary compound structure. In other cases, the resin has not been cured, in which case the resin introduced in the vacuum infusion process serves both to adhere the blocks to each other and to the inner and outer layers, as well as to manufacture the blocks and the inner and outer layers in one. single unitary structure. In such a structure, the portions of the resin-impregnated wrapping layers that traverse between the inner and outer layers act as structural reinforcement layers in the resulting building panel.

FIGURE 30 illustrates yet another embodiment of building panels of the invention. In the embodiment illustrated in FIGURE 30, the foam blocks 32 are pre-wrapped by fiberglass layers 190, the same as the pre-wrap discussed above with respect to FIGURE 29. Thus, fiberglass layers 190 are pre-wrapped. - wrapped around the foam blocks, and optionally cured, before the foam blocks are assembled on the building panel. Unlike the structure of FIGURE 29, in the structure illustrated in FIGURE 30, no pins 123 are used to reinforce the building panel. Instead, each third foam block is oriented 90 degrees so that the narrowed edges 198 of the respective wrapped foam block elements are oriented towards the inner 34 and outer layers 36. Thus, in FIGURE 30, foam blocks 32B, 32E, and 32H form a second set of foam blocks which are thus oriented. The remaining foam blocks, for example 32A, 32C, 32D, 32F, 32G, and 321 represent the first set of foam blocks.

The blocks 32B, 32E, and 32H thus perform as structural reinforcement elements, previously illustrated as pins 23 and 123, and are hereinafter referred to as pins.

In the first set of foam elements / blocks, the relatively broader sides 199 of the foam elements turn towards the inner and outer layers. In the second set of foam elements, the relatively broader sides 199 of the foam elements rotate along the length of the building panel.

In some embodiments, and depending on the specifications requiring structural strength to be contributed by the structural reinforcing foam pins 32C, 32F, the foam density on the reinforcing foam pins illustrated as 32B, 32E, and 32H may be greater than the foam density in the remaining foam blocks in order to achieve the desired level of structural reinforcement. In other embodiments of FIGURE 30, the structural requirements of foam pins 32B, 32E, and 32H are relatively lower, so that the foam density on foam pins 32B, 32E, and 32H may be the same as density on foam blocks. remaining foam. In still other embodiments, the foam density on foam pins 32B, 32E, and 32H may be less than the density on the remaining foam blocks. Thus, foam density can be specified as an element in achieving the desired level of resistance that is contributed by the rotated foam block pins 32B, 32E, and 32H. Alternatively, or in combination, such reinforcement resistance may be captured according to the thickness and rigidity of the wrapping layers 190 around respective foam block pins 32B, 32E, and 32H. In some embodiments, the wrap layers 190 around respective foam block pins 32B, 32E, and 32H are the same as wrap layers 190 around the remaining foam blocks. In other implementations, the wrapping layers 190 around the foam block pins 32B, 32E, and 32H are thicker or otherwise stiffer than the layers 190 around the remaining foam blocks to achieve levels. higher strength and stiffness in the pins.

In light of the pre-wrapped foam block structures 32, the fiberglass reinforced wrapping layer 190 can serve the functions of both or both the inner layer and the outer layer 36, whereby the layers 34 and 36 are optional building panel elements of FIGURE 30.

In any event, the strength provided in the reinforcement block pins 32B, 32E, and 32H can be manipulated by selectively specifying both the foam density in the respective blocks and the thickness and other characteristics of the fiberglass reinforced wrap layers 190. Determining the structural orientation of blocks of

foam 32 in FIGURE 30, desirable width and thickness dimensions for the wrapped foam blocks, including the foam block pins, including wrap layers 190, are 16.51 cm wide and 7.62 cm 30 thick . Such dimensions provide a commonly used depth "Tl" of spacing 131 between the pins of approximately 8.89 cm, assuming the thickness of the inner layer 34 to be minimal. The illustrated structure, and again assuming minimal thickness of the inner layer 34, also provides a commonly used center-to-center distance "T2" between the 40.64 cm foam block pins.

Given the above dimensions, the size of the space 131 between a pair of adjacent pins is the same as the conventional depth, i.e. 8.89 cm of conventional wooden pin spacings, and a width of 33.02 cm. In addition, the 4.64 cm center-to-center spacing of the foam block pins provides for conventional attachment of conventional building materials such as 121.92 cm wide laminate 129 within the building panel. Thus, the embodiment of FIGURE 30 provides an interface on the inner surface of the building panel to which conventional materials can be combined, bonded using conventional fastening technology and

conventional dimensions.

The embodiment of the building panel illustrated in FIGURE 30 may be manufactured according to a process similar to that illustrated in FIGURE 25. Starting with the process illustrated in FIGURE 25, the pins 123 are omitted and the weave layer is omitted. The first stack of foam blocks places two blocks side by side over the outer layer precursor. The second stack of foam blocks is oriented to place the foam blocks on edges 198 rather than on sides 199.

The embodiment of FIGURE 30 may also be made by the above-mentioned vacuum infusion process, and where the wrapping layers 190 may or may not be pre-infused, in whole or in part, and may or may not be cured when placed in the process. vacuum infusion

Pre-wrapped foam blocks 32 in the embodiments of FIGURE 30 may be replaced by other structural reinforcement structures, such as pins 23 of FIGURE 6. Another replacement structure is a pultruded pin having walls about 0.045 cm thick. and approximately 1.27 cm thick. By engineering the thickness of the pultruded stud walls, the width of 7.62 cm of the reinforcement elements can be reduced, such as to 3.81 cm, with corresponding increase in the widths of the smoothly placed foam blocks, whereby the width of the The resulting cavity 131 is 36.83 cm.

Or by wrapping the foam block 32 into additional, or thicker, layers of fiberglass reinforced resin, the strength contribution of the fiberglass wrap may be increased sufficiently to allow the width of the foam block to be reduced. to 3.81 cm, over which cavity width 131 is again 3.83 cm.

As desired, the width of a pin 123 may be greater than 7.62 cm, such as 10.16 cm, 12.7 cm, or 15.24 cm, with corresponding adjustment in the widths of the flat laid foam blocks to reach a desired center-to-center spacing of the foam blocks such as 40.64 cm center to center or 60.96 cm center to center.

FIGURE 31 illustrates yet another structure for the fiber reinforced polymeric building panels of the invention. In FIGURE 31, a series of fiberglass reinforced layer elements 200 collectively function in the capacities previously described for inner layer 34, outer layer 36, and weave layer 50.

Each layer element 200 extends

(i) from a first end 202 thereof adjacent an outwardly facing first side 204 of a first foam block along the outwardly facing surface 255 of a second foam block to a

second side 206 of the second foam block in place of the outer layer 36,

(ii) thus extends between that first side 206 of the second block and a first side 208 of a third foam block as a reinforcing element 209 in place

from the weave layer 50 to the inwardly facing sides 210 of the second and third blocks,

(iii) thus extending along the inwardly facing side 210 of the third foam block in place of the inner layer 34 to an inwardly facing side

20 of a fourth foam block and to a second end

212 of the layer 200 adjacent the inwardly facing side 210 of the fourth foam block.

The first 2 02 and second 212 ends of a given element 200 overlap the layer elements.

200 in which the reinforcement elements 209, whereby each layer element overlaps or submits three of the reinforcement elements 209 and reaches proximity to four of the

Foam blocks.

The representation of layers and layer elements in the

FIGURE 31 is exaggerated to show the production of layers. In actual structures, the overlapping end portions of a given layer member 200 are generally received within the underlying portions of the adjacent layer members 200, with modest deformation of the underlying foam block to form a relatively flat main inner surface. 25 and a relatively flat outer surface 56. Thus, in the embodiment of FIGURE 31, each of the inner layer 34 and outer layer 36 is constructed from portions of multiple layer elements.

Pins 123, as illustrated, are optionally added as desired in the embodiments of FIGURE 31.

Generally speaking of the invention, fiberglass layers used in the invention, such as and without limitation, layers 34 and 36, may also be made using the well-known spraying method. In the chopped spray method, a fiber layer is sprayed or sprayed onto a substrate, and then covered with a resin spray. The resin impregnates the pulverized fiber layer and is cured to develop into the fiberglass impregnated layer.

For example, the chopped spray method, or any other known method of manufacturing fiberglass panels, may be used to fabricate the outer layer 36 and the inner layer 34. Such inner and outer layers may then be joined together by e.g. For example, the pre-wrapped foam blocks produce the final assembly using both additional resin and suitable construction adhesive. Pins 123 may be added as desired on the outer surface of the inner layer using both hardenable resin and construction adhesive.

Alternatively, the inner layer, the outer layer, and the weave layer may be prefabricated as resin impregnated fiberglass hardened layers. The prefabricated weave layer is in the configuration shown for example in FIGURE 8. Foam blocks are optionally added to the cavities on either side of the weave layer. The weave layer, the inner layer, the outer layer, and the foam blocks, if used, are then joined together using either additional fluid-able resin or building adhesive, or a combination of adhesive and resin, optionally in combination. a vacuum process, optionally a

vacuum infusion process.

FIGURE 32 shows yet another embodiment of the panels.

of construction of the invention. Inner layer 34 and outer layer 36 are as discussed above with respect to for example FIGURE 8. Foam blocks 32 are omitted. With the foam blocks omitted, the structural reinforcement element, previously illustrated herein as a weave layer 50, can assume a wide variety of configurations. The spaces between the structural reinforcement elements are empty. For example, the structural reinforcement member may for example be a polygonal honeycomb structure 194. While the honeycomb layer 194 may represent a wide variety of structures the regular hexagonal structure shown is believed to be highly cost effective. strength per unit mass of the honeycomb structure. The structure surrounding a given cell / cavity 196 may be fabricated using a single layer, for example, resin impregnated fiberglass, or multiple layers of resin impregnated fibrous material. For example, with respect to FIGURE 32 specifically, the lower half of the honeycomb layer may be fabricated using a first such layer and the upper half may be fabricated using a second such layer. A given cell 196 may span the full thickness of the space between the inner layer 34 and the outer layer 36 as illustrated, or may span less than the full thickness such as half the thickness, or less, under which, for example, 2, or 3 or more cells may be used to span the full thickness of the space between the inner and outer layers.

The cells 196 may or may not contain thermally insulating material such as closed cell foam as used in foam blocks 32 in other of the illustrated embodiments. Where insulation foam is used, for example, an on-site foam process may be used to install the foam over the respective cells.

As an additional illumination of the void embodiments represented by FIGURE 32, the structural reinforcement element may be the weave layer 50 as illustrated in FIGURES 8 and 26, or a more robust embodiment of such a weave layer 50, without inclusion of the foam insulation, illustrated as FIGURE 33.

In the embodiment illustrated in FIGURE 33, the pin width 123 defined between members 128 is 3.81 cm. Given the center-to-center distance "T2" between the 40.64 cm studs 123, the width of the spacing 131 adjacent the studs is 36.83 cm, which corresponds to the conventional width of commercially available fiberglass batten insulation panels. glass.

In addition, the structural reinforcement element may be the wrapping layers 190 illustrated in FIGURES 28, 29, and 30 again with the omitted foam blocks 32 of the frame. Reflecting on both FIGURES 32 and 33, the space between the inner and outer layers may be occupied by materials having a wide variety of other configurations including, without limitation, circles, ellipses, oval and other arcuate figures, triangles, and other polygons as well as a wide variety of grooved structures.

FIGURE 34 shows a cross section of a building panel of the invention where inner layer 234 and outer layer 236 are integral with structural reinforcement connecting member 250. Pins 123 may be used 20 as an option, for example. to create a cavity 131 for passing utilities or for adding insulation, or to further contribute to the strength of the building panel. The building panel as illustrated in FIGURE 34 may be made by, for example, a continuous pultrusion process wherein the illustrated cross section is representative of the product exiting the pultrusion die. The pultruded product is continuously produced and cut to conventional lengths representing the height of a straight construction panel used for example in a wall structure. The upper and lower cutting ends are covered by upper and lower plates as desired, either in the manufacturing process or prior to installation at the construction site.

Since the closed cavities 196 in the frame are empty, all strength in the frame is derived from structural members 234, 236, and 250. Thus, structural members 234, 236, and 250 are designed as structural members in themselves and of each other. themselves, whereby the inner layer 34, the outer layer 36, and the connecting member 250 have relatively greater thicknesses than the thicknesses of the layers 34, 36, and 50 in the embodiments of e.g. The thicknesses of the layers 234, 236, and 250, in the example illustrated in FIGURE 34, may be, for example and without limitation, between approximately 0.10 cm and approximately 1.27 cm for building panels to be used for industrial construction. light or commercial light or normal residential.

Cavities 196 may be used as utility passages as desired. In any of the pultruded structures, cavities may be filled with insulation foam or other known insulation materials as desired, for example and without limitation, by injecting the foam material as a later stage of the pultrusion process. Any stiffness provided by such insulation material, if any, can be considered when designing especially the thicknesses of elements 234, 236, and 250.

Exemplary end structures of the pultruded building panels, and articulators of adjacent panels, are shown in FIGURES 34 and 34A. FIGURE 34 shows a male / female end combination on a building panel 14A. Each panel has a male end 216 and a female end 218. FIGURE 34 shows male end 216 of panel 14A joined to, received within, female end 218 of a second panel 14B. FIGURE 34A shows end pivot structure where both ends 220 of a panel defines a first step 222A, 22B and a second step 224A, 224B, each panel having the same end frame at both ends, and all panels having a common end frame. In FIGURE 34A, end 22OA of panel 14A is joined with end 220B of panel 14B.

FIGURE 34B shows the first and second pultruded panels 14A, 14B, similar to the panels shown in FIGURES 34 and 34A, including connecting elements 250. In FIGURE 34B, each panel has a single end 22OA and a receiving end 220B. A reinforcing pin 123 is integral with the receiving end 220B. The single end 22 OA of the second panel 14B abuts against and is joined to the receiving end 22OB of the first panel 14A in producing a wall structure, ceiling structure, or floor structure; and the inner layer 234 of the second panel 14B abuts against and joins with the outwardly facing surface 226 of pin 123 on adjacent panel 14A.

Once the panels are cut, the panels 30 can be joined end to end using end structures that were fabricated as part of the process for initially fabricating the panel. Where an initially fabricated end frame of a panel is cut, such as at the construction site, the cut end of that panel may be joined to another panel using an "H" support 140.

FIGURE 35 illustrates a building panel made using a series of individually wrapped foam blocks 32 in combination with spaced hollow pultruded pins 123. An outer layer extends along the bottom of the illustrated structure. An inner layer 34 extends along the top of the illustrated structure, and overlaps both the foam blocks and the pins. A determined pin 123 extends from an outer layer closed end wall 126, along members 128, past the main inner surface 25 of the panel on inner block surfaces 32, and further passes into the blocks 32 and away from the outer layer 36, to the end panel 13 0. The end panel 130 of each pin is moved between approximately 2.54 cm and approximately 13.97 cm from the inner surface 25 so as to define spaces 131 between the pins. Such a pin can be made by applying resin to a fabricated fiberglass layer and curing the resin. Alternatively, such a pin may be made by a pultrusion process.

An inner layer of fiberglass reinforced polymer is applied over both flat laid blocks 32 and pins 123.

A hollow space 133 is defined within each such pin. The hollow space 133 may be filled with thermally insulating foam as desired. The panel illustrated in FIGURE 35 is thus a combination of foam blocks 32 encased in fiber reinforced polymer layers, and hollow pins 123. Where pins 123 are pultruded pins, the panel represents a combination of pultruded pins and foam blocks. involved.

FIGURE 36 illustrates a building panel made using a series of individually fabricated rectangular fiberglass reinforced polymeric pultruded blocks 232 in combination with spaced hollow pultruded pins 223. Each pin 223 has an outer layer closed end wall 126, and extends along the members 128, past the main inner surface 25 of the panel on inner surfaces of the flat placed pultrusions 232 and away from the outer layer 36, to the end panel 130. The end panel 130 of each pin it is moved about 2.54 cm and 13.97 cm from the inner surface 25 to define spaces 131 between the pins. A pultruded reinforcing web 238 extends through the proximal pin, optionally generally in alignment with the main portion of the inner surface 25 of the panel.

Both pultruded blocks 232 and pultruded pins 223 are illustrated with hollow spaces 133. In another, unshielded embodiment, the insulation foam, for example polyurethane foam, is injected into the hollow spaces in one or both blocks 232 and pins 223, providing improved thermal insulation characteristics. FIGURE 37 illustrates a vacuum molding processing that can be used to produce building panels of the invention. FIGURE 38 illustrates a building panel made by such a vacuum molding process.

Referring to FIGURES 37 and 38, a specific example of a process for producing a building panel of the invention is described in some detail. In FIGURE 37, numeral 300 represents a lower female-type mold member that includes a plurality of elongated female-like recesses 320 spaced e.g. 40.64 cm center to center. The number 306 represents the mold and upper element.

At the beginning of the process, the upper and lower mold elements, including recesses 302, are optionally coated with mold release material. Alternatively, a mold release agent may be incorporated into the resin. Thereafter, foam pin blocks 323, pre-wrapped with fiberglass layers 308, are placed within recesses 302. Foam pin blocks 323 and recesses 320 are thus sized and configured so that the foam blocks fit snugly into the recesses, and the upper surfaces of the foam pin blocks are generally co-planar with the upper surface 304 of the lower mold element.

As part of the process of placing the foam pin blocks in the recesses, each foam pin block is extracted through a resin wetting machine which applies liquid resin coatings on three of the four elongated surfaces of the foam block. The three surfaces that are coated are the bottom surface and the two side surfaces as indicated by arrows 310 in FIGURE 37. Thus, the three pin block surfaces 323 that are received against surfaces of the bottom mold element are coated with resin. leaving the upper surfaces 311 of the uncoated pin blocks dry. Thus, the upper surface of the assembly at this stage of the assembly process, which comprises the upper surface 304 of the lower mold element and the upper surfaces 311 of the pin blocks, is generally free of liquid resin.

Thereafter, a dry layer 343 of 0.623 kg fiberglass fabric, which will become the inner layer of the construction panel thus manufactured, is unrolled from a roll of such assembled material adjacent to for example the right end of the table. as shown in FIGURE 37 and is lifted over the lower mold element from right to left. Since the upper surface of the grouping is generally resin free, the fabric layer can be easily pulled and dragged over the upper surface of the grouping. The dry fabric layer is placed over the entire length and width of the lower mold element, including the upper surfaces of pin blocks 323.

Next, foam blocks 32, pre-wrapped with fiberglass layers 314, are laid flat on top of the dry, edge-to-edge fabric as shown in FIGURE 37. As part of the process of placing the foam blocks placed flat on the dry fabric, each foam block 332 is first coated in two, optionally three, of its four elongate layers with a liquid resin coating. The two surfaces that are necessarily coated are the bottom surface 316 and both the left side surface 318 and the right side surface 320, both as shown in FIGURE 37. FIGURE 37 illustrates the bottom surface and the left side surface as being coated as shown. indicated by the arrows 312 in FIGURE 37. Optionally, the right side surface may also be resin coated at the same time.

Thus, at the time when all blocks 332 had been placed on the dry layer 334, a resin layer was placed over the entire upper surface of layer 334 by the resin on the lower surfaces of blocks 332. In addition, the Resin applied to one or more side surfaces of the foam blocks readily transfers in part to the side facing surfaces of the adjacent foam blocks. Or if both left and right side surfaces of foam blocks 332 were resin coated, then the coatings on the side facing surfaces converge and cooperate with each other. As part of the process of placing foam blocks 332 on layer 334, and if only one side surface of the blocks 332 is being coated with resin, the otherwise uncoated side surface of the end ends of the foam blocks is coated with resin. both side surfaces, whereby the outwardly facing side surface of the last placed foam block 332 is also coated with resin.

At this stage of the process, foam blocks 332 collectively form a dry upper surface 324 of the member group, generally free of liquid resin. Then, another dry layer of 0.623 kg fiberglass fabric, which will become the outer layer 336 of the thus fabricated building panel, is unrolled from the roll of such mounted material adjacent to for example the right end of the vacuum table. and is pulled over the dry flat laid foam blocks 332 from the right side of the mold 300 to the left side of the mold. Since the upper surfaces of foam blocks 332 are generally resin free, the fabric layer can be easily pulled and dragged over the upper surface 324 of the foam blocks, which form the upper surface of the assembly at this stage. Layer 336 of dry fabric is placed over the entire foam block array 332, whereby layer 336 becomes the surface

top of the grouping.

Resin is applied to the upper surface of layer 336, such as by a drip coating, a roll coating, a liquid curtain coating, or other known surface coating process, providing a resin coating over the entire upper surface. of the grouping. At this stage of the assembly, all side and bottom surfaces of foam blocks 323 and 332 are coated with liquid resin, and the upper surfaces are uncoated. In the case of foam blocks 323, the inner layer 34 is then adjacent to the dry upper surface of the foam blocks 323, and a resin layer is located on the upper surface of the inner layer 334, whereby the dry upper surfaces of the blocks. 323 are separated from the resin by only the inner layer 334.

In the case of foam blocks 332, the outer layer 336 is then adjacent to the dry upper surface 324 of foam blocks 332, and a resin layer is located on the upper surface of the outer layer 336, whereby the dry upper surfaces of foam blocks 332 are separated from the resin by only the outer layer 336.

The upper and lower mold elements are then sealed together to form a closed and sealed mold with the respective construction panel elements in the mold cavity.

The mold cavity is then evacuated, which extracts a vacuum that substantially removes all air from the cavity. As air is extracted from the cavity, resin flows to all areas of the mold where air has been removed, including through layers 34 and 336, to thereby fill all voids left by the air evacuation and to form a continuous resin matrix around and through all layers 334, 336, and fiberglass wrapping layers 308 and 314 comprising foam blocks 323 and 332.

Thus, the resin flows down through layer 34 and in close agglutination contact with the upper surfaces of foam blocks 323. The resin also flows down through layer 336 and in close agglutination contact with the surfaces. foam block tops 332. As a result, the resin in the mold flows to all areas that have been evacuated by removed air, thereby creating a continuous resin matrix throughout the structure on all fiberglass layers. However, in cases where the foam in foam blocks 323 and 332 is a closed cell foam, the resin generally does not penetrate beyond the outer surfaces of the foam blocks. Where the foam is an open cell foam, the resin may penetrate deeper into the foam blocks as permitted by the foam permeability.

Once the mold has been closed and evacuated, the resin is cured in the mold. In the resin cure process, the mold may or may not be heated depending on the thermal requirements associated with the specific resin cure being used. Where heat is needed, the same is applied. Where heat is not required, the resin is usually cured.

at room temperature.

After curing, the cured fiber-reinforced polymeric building panel product is removed from the mold. The mold is cleaned if and as needed, and the process is repeated to produce another building panel.

FIGURE 38 illustrates a building panel made in accordance with the process described with respect to FIGURE 37. The process of FIGURE 37 may be used to produce building panels that are cost effective in using stress point materials which readily combined with conventional building materials using conventionally recognized standardized element spacings. Thus, in the embodiment illustrated, foam blocks 332, including the wrap and resin layers, are 2.74 m long, 20.32 cm wide, and 7.62 cm thick between layers 334 and 336. Blocks The spindles extend 7.62 cm from layer 334, are 5.08 cm wide, and 2.74 m long. Layers 334 and 336 are 2.74 m wide and are as long as the panel length. The layers 308, 314, 334, and 336 are all made of the same 0.653 kg fiberglass fabric and thus all the same thickness when filled with resin. The resulting thickness of each such layer is approximately 0.9 mm. In the determined structure, the outer layer 336 plus the adjacent portion of wrapping layer 314 is thus uniformly 1.8 mm thick. Similarly, the inner layer 336 plus the adjacent portion of wrapping layer 314 is uniformly 1.8 mm thick. In addition, the collective thickness of the reinforcing portions 30 of the wrapping layers between each pair of foam blocks 332 is 1.8 mm. The outer surface of the building panel is tensioned by lateral loading and water pressure. The inner layer is tensioned in tension by lateral loading. The reinforcing portions are tensioned both by side loading and compression loading. Accordingly, all highly stressed areas of the building panel are developed to a common thickness of the fiber reinforced polymeric material, with no overlap of excess material anywhere in any of the outer layer structures, inner layer structure or Reinforcement elements, resulting in efficient use of materials and structure.

In another embodiment, not shown, all elements shown in FIGURE 37 are assembled in the dry mold, i.e. without addition of any resin within the mold before the mold is closed. The resin is then infused into the mold after the mold is closed and as air is being evacuated from the mold. Such a process is known as an infusion process, which is also an accepted process for producing building panels of the invention.

FIGURE 39 shows a side elevational view of a portion of a building panel 14 of the invention as viewed from the outer layer 36. The outer layer 36 and inner layer 34 are fiber-reinforced polymeric layers. such as those described with respect to FIGURES 6 and 8. Structural reinforcement connecting member 250 is configured in the form of a honeycomb structure where each honeycomb wall wraps the thickness of the building panel between the outer layer 36 and the outer layer. 34. The walls 250 of the honeycomb structure serve as straight reinforcement elements between the inner and outer layers 34, 36, and provide strength and stiffness as the reinforcement elements.

structural of the building panel.

The dimensions of the honeycomb cells, as well as the thickness of the cell walls 250, can be designed for the desired anticipated horizontal and vertical loads. The "T3" dimension across the honeycomb cell is usually between about 0.63 cm and about 5.08 cm. The thickness of a connector 250 is usually between about 0.05 cm and about 0.50 cm. Cell size and binder thickness have known ratios that can be used by those skilled in the art to design honeycomb construction panels having desired structural strength characteristics.

The honeycomb structure shown in FIGURE 39 is generally representative of a family of building panels having both straight structural reinforcement members 50 and transversely extending structural reinforcement members. The transversely extending structural reinforcement elements extend between, and are optionally connected to, the straights of the structural reinforcement elements. The combination of straight structural reinforcement elements and transversely extending structural reinforcement elements can define regular or irregular open or closed geometric shapes, which optionally generally extend continuously between inner layer 34 and outer layer 36. FIGURE 39 illustrates a regular hexagon as an example.

of regular geometric shapes.

Pins 123 may be used as an option, for example to create a cavity 131 for utility passing or to receive a fiberglass insulation slat, or to further contribute to the strength of the building panel.

The building panels illustrated in FIGURES 30-34 may employ upper plates 20 and lower plates 16 in the same manner as described with respect to the embodiments illustrated for example in FIGURES 8 and 9.

Throughout this teaching, fiber reinforced pins 123 have been illustrated and taught to have an end panel 130, first and second members 128, and outwardly extending flaps 126. See, for example, FIGURE 8. The invention contemplates Still pins 123 are structured as closed structures, such as an optionally stripped, closed-perimeter rectangular tube 126. The invention further contemplates a pin 123 as a pultruded structure, in both illustrated flap cross-section and closed-perimeter cross-section. .

Pins 123 may be located over a structural reinforcement member 50, 209, 250, as at 123A in FIGURE 31, or away from the structural reinforcement member

as illustrated in FIGURE 33.

Among the requirements of the structural reinforcement element is that the materials in the structural reinforcement element cannot be sensitive to, susceptible to substantial degradation by water or any inclusions commonly found in water, whether dissolved minerals or organic materials such as life forms that live in or transform fiber compositions. That is, materials cannot be susceptible to water degradation or anything in the water, to the extent that such degradation will lose the ability of the structure made from such panels to provide the compressive strength necessary to support construction loads. and the folding loads imposed by underground forces, and

above average climate forces.

Consequently, the structural reinforcement element

usually does not include wood fiber structures

Uncoated grooves commonly referred to as grooved cardboard structures, or any other fibers whose strengths are substantially affected by moisture or moisture vapor, and any inclusions that may be expected to occur in moisture found on or around the ground adjacent to a building structure. . In addition, the fibers cannot be susceptible to insect infestation or any other degrading factors. Thus, the fibers are inert inorganic materials as illustrated elsewhere herein.

Alternatively, susceptible fibers may be used where such fibers are combined with sufficient coating for example of a resin to prevent such harmful elements from reaching the fibers during the expected life of the building panel; or where one or more layers disposed out of a fiber layer in the panel is capable of preventing sufficient moisture from trapping the fibers so that the fibers may become degraded.

As a result of exposure to moisture.

In either embodiment of the invention, one or more gel coatings may be applied to the panel structure on one or both inner and outer surfaces.

Any materials used for reinforcing fiber, foam, and resin, all such elements, including UV inhibitors and fire retardant additives, are chemically and physically compatible with all other elements with which they will be in contact. , so that no harmful chemical or physical reactions appear in

wall systems of the invention.

One of the substantial benefits of wall structures made using the teachings of the invention is that the wall structures are waterproof and moisture proof. For example, in areas where hurricanes are frequent, building codes require concrete structure on above-average residential walls. Experience has shown that hurricane force winds rain heavily through such concrete wall structures so as to cause substantial water damage even when the building structure itself is undamaged.

In contrast, wall structures of the invention are essentially waterproof; and such a waterproof feature is not affected by rain brought on by hurricane. The layer 36 itself is waterproof. While layer 36 is very hard for water to penetrate, even if the outer layer 36 is split, foam blocks 32 are waterproof by the fact that the individual cells of foam blocks 32 are closed cells. If the foam layer is also split, the inner layer 34 is also waterproof. In addition, where the weave layer is used, before the slit force reaches layer 34, it must pass through the weave layer 50, which is another hard and waterproof layer, either layer 50. be found adjacent to layer 36 or adjacent to layer 34. In any event, any slit force must penetrate multiple waterproof layers, at least two of which are substantially hard layers when considered in light of the types of forces that are normally imposed on buildings by weather or other normal external loads. Non-foam structures are similarly effective barriers to water penetration. With respect to the joint between the bottom of the wall panel and the bottom plate, such joint may be filled with curable resin, adhesive, caulking, or other barrier material, to positively block any water penetration of the joint between the panel. wall and bottom plate.

Similarly, vertical joints in the foundation wall utilize for example "H" bracket 146 which can be closed to water penetration by applying curable resin, adhesive, caulking, or other waterproof coatings to the joint. In addition, as mentioned elsewhere herein, adhesives, resins, and the like may be applied to the building panels and / or the various supports before the supports are applied to the respective building panels, thereby providing waterproof characteristics. additional to the finished foundation wall, or above-ground wall.

The building panels of the invention find use in a variety of light, residential industrial and commercial building applications. The strength and other specifications of a given wall panel are specified according to the loads to be imposed during the anticipated construction life.

Wall structures of the invention find application in and as, for example and without limitation, the construction of foundation walls; opaque walls, for example, in buildings without foundation; fabricated residential base curtain walls; floor systems; ceiling systems, roof systems; above average exterior walls; curtain walls as in high rise building replacement concrete block; and exterior walls in areas that use mansory exteriors, such as in coastal construction. Although the specifications and designs have focused on foundation walls, the principles described herein apply in the same way to other uses of panels and fittings of the invention.

A variety of part fittings can be used with designs using walls of the invention, for example and without limitation, 10-beam / girdle columns, fiber-reinforced decks that optionally include structural upper and lower column wedges, corner supports interior, exterior corner brackets, "H" channel brackets, top plate connectors, garage floor shelves, 15 support brackets, floor and garage bulkhead brackets, service door cuts, garage door cuts, opaque wall transitions, and pin cutouts.

In addition, resin and fiber patch kits may be mentioned for use to patch up a damaged building panel, angled wall connectors, complete garage transition foundation wall, opaque wall turns, top and bottom plate clamping together. with potential transport advantages where the upper and lower plates are fixed to the construction site, beam pockets, column wedges at the base to distribute load, and window trestles. Fasteners may also be mentioned for applying exterior product and for providing connections to other parts of the building. Such fasteners may be, for example and without limitation, composed of fiber or metal reinforced polymer. A wide variety of fittings can be attached to the wall frame using adhesives conventionally available for field applications.

A specified advantage of wall systems of the invention is that such wall systems can be readily sized and configured for use with standard size conventional construction products already available, for example building materials.

Construction panels of the invention may be cut using conventional tools commonly available at a construction site to suit the needs of the hand job. For example, a panel may be cut to length. A window opening can be cut. A door opening can be cut. Perforations of 15 utilities of the foundation wall may be cut, such as for furnace fresh air or flue gas exhaust, or the like, or such utilities may be passed into cavities 131 between pins 123 and inwards or inner layer 34 .

Advantages of the invention include, without limitation, a

bottom composition plate that has the potential to provide a wider footprint to the underlying floor than the projected area of the wall panel to distribute the overweight of the building. The bottom plate may be applied on site or off site. The wall structures of the invention are lightweight compared to the concrete structures they replace. The wall structures of the invention are waterproof, versatile, mildew resistant, termite resistant, and rot resistant. The substantial polymeric component of the wall structure compositions of the invention provides a desired level of radius barrier according to existing building codes whereby the polymeric layer conventionally used on the outside of the foundation wall is not required, and may be omitted. , along with corresponding saved in material and labor costs.

Standard wall structures of the invention may be installed by handwork, and do not require any large machines to be brought to the construction site for the purpose of installing a foundation, foundation wall, or above-average wall, no slab truck. , no crane to install the building panels.

The invention does not contemplate larger, for example, thicker, higher, and / or longer wall panels, which may weigh at least 113.39-340.19 kg or more, under which a load lifting device such as a light load crane, is optionally used to install such

2 0 wall, with corresponding reduction in labor cost.

In addition, where a wall or roof panel is being raised above the ground floor, a suitable weight crane facilitates such a taller installation.

Wall structures of the invention may be installed in all seasons and all climates, provided that the excavation can be dug in a suitable natural support base. Panels of the invention are environmentally friendly. Panels of the invention are consistent with the quality requirements of Green constructions and / or

Energy Star constructions by which constructions constructed with building panels of the invention may qualify for such classifications. No moisture proof required. Once the foundation walls are in place, the interior of the space thus enclosed is ready to be finished. HVAC cavities are available between pins 123. Plumbing and power can also be easily connected through the walls, again between pins 123, optionally within pins 123.

Additional insulation can easily be installed in the wall cavities between pins 123, thereby achieving for example at least insulation factor R26. Building panels can be repaired more readily than concrete. Openings can be cut more easily than concrete. Wall changes can be made more easily than concrete. Any normal wall height can be achieved. Building panels can be installed on an aggregate stone base, whereby no dumping of a concrete base is required. Thus, the lower level wall of the building can be finished with no need for any ready mix concrete at the building site.

The insulation property acquired as part of the wall structure can be approximately R-15 without additional insulation installation by using 7.62 cm of R-15 per cm of foam insulation blocks 32. Additional insulation can be added to the wall. cavity 131 to increase the thermal insulation value of the wall. Alternatively, the thermal insulation value of the wall may be increased by increasing the wall thickness between the inner and outer layers by using corresponding thicker foam blocks 32 and filling the entire space with the foam blocks.

Wall structures of the invention have multiple desirable properties, including being fire resistant where fire retardant ingredients are included in the resin formulation, being a good barrier to ultraviolet rays, providing good sound attenuation, and generally free from insect infestation. , not being generally susceptible to infestation by decaying organisms, being a good barrier against water, and being a good barrier to radon gas transmission.

Wall structures of the invention are firm, durable, and have very favorable expansion and 15 contradiction ratings compared to the concrete they replace. Wall structures tolerate a wide range of temperatures such as those found in building construction. The building panels of the invention are easy to transport to the building site. Building panels can be mass-produced and do not have to be project specific such as known insulated wall systems that are out-of-the-box, and transported to the building site as prefabricated wall systems.

2 5 Wall, Ceiling, Roof, and Floor Structures of the Invention

they can be installed in locations where it is difficult to achieve ready mix concrete delivery, such as islands, restricted weight areas, high elevation curtain walls, and the like.

Although the invention has been described with respect to various embodiments, it should be noted that this invention is also capable of a wide variety of other and additional embodiments within the spirit and scope of the appended claims.

5 Those versed in technique will now see that certain

Modifications may be made to the apparatus and methods discussed herein with respect to illustrative embodiments, without departing from the spirit of the present invention. And while the invention has been described above with respect to preferred embodiments, it will be understood that the invention is adapted for various rearrangements, modifications, and alterations, and all such arrangements, modifications, and alterations are intended to be within. the scope of the appended claims.

To the extent the following claims use more function language meanings, it is not intended to include here, or in the present specification, anything not structurally not equivalent to that shown in the embodiments described in the specification.

Claims (82)

1. Resin-based fiber-reinforced composite structural construction panel designed and adapted for use in the construction of a building, said construction panel having a defined height between an upper part and a lower part of the said building panel when said building panel is in a vertical use orientation, length, and thickness, said structural building panel comprising: (a) a fiber-reinforced outer polymer layer, said outer layer defining a an outwardly facing surface of said building panel when said building panel is being used in a building wall; (b) a fiber reinforced inner polymeric layer, said inner layer defining an inwardly facing surface (57) of said building panel when said building panel is being used in a building wall; (c) a plurality of structurally supporting pins (23,123, 223,323) spaced along the length of said building panel and extending inwardly from the inwardly facing surface (57); and (d) channels between said pins, such channels being sized and configured to receive utility passages, whereby the inner sheet material (129) may be placed over said pins thereby hiding such utility passages from view. in casual lifting. Resin-fiber reinforced composite structural construction panel according to Claim 1, characterized in that a number of structural reinforcement elements extend between the upper and lower part of said construction panel; said structural reinforcement elements, at locations spaced along the length of said building panel, extending between locations at or near said outer layer and locations at or near said inner layer, and thereby define spaces between said inner layer and said outer layer and between said respective structural reinforcement elements. Resin-based fiber reinforced composite structural panel according to Claim 1 or 2, characterized in that said inner and outer layers comprise resin-impregnated fiberglass layers, optionally said panel. further comprising at least one fiber-resin composite top plate and one fiber-resin composite bottom plate. Resin-fiber reinforced composite structural construction panel according to any one of claims 1, 2 or 3, characterized in that said construction panel has a vertical crush strength of at least 5950 kg / m , optionally at least 8925 kg / m 2, and optionally a horizontal point shear moment resistance of at least approximately 9 758 kg / m 2 between the top and bottom. Resin-fiber reinforced composite structural construction panel according to any one of claims 1, 2, 3 or 4, characterized in that the various pins (123, 223, 323) are spaced apart along the length of said building panel and generally extending between the top and bottom, said pins extending away from said inner layer and said outer layer in a common direction, optionally said various pins (123, 223, 323) extending inwardly in a common direction from the inwardly facing surface (25) between about 2.5 cm and approximately 15.2 cm, said various pins being arranged generally parallel to each other. itself, and extending away from said outer layer, said building panel optionally comprising insulating foam elements; that extend between and are in surface-to-surface contact with said respective inner and outer layers. Resin-based fiber-reinforced composite structural construction panel according to any one of claims 2, 3, 4 or 5, characterized in that said structural reinforcement elements are comprised of a forward weaving fabric. and backwards, as said structural reinforcement elements, in passages extending over a distance separating said inner layer and said outer layer, the passages being spaced along the length of said building panel, said layer extending along at least one of said inner layer and said outer layer between said passages, and wherein the first portions of said weave layer form unitary structural elements with second portions of at least one of said inner layer and said outer layer between the spaced passages said structural reinforcement elements comprising fiber reinforced polymeric elements optionally spaced from each other along the length of said construction panel at distances between approximately 10 cm and approximately 61 cm. Resin-based fiber reinforced composite structural construction panel according to any one of claims 2, 3, 4, 5 or 6, characterized in that at least one of said inner layer and said outer layer has a nominal thickness between approximately 0,076 mm thick and approximately 3,8 mm thick. Resin-fiber-reinforced composite structural construction panel according to any one of claims 1, 2, 3, 4, 5, 6 or 7, further comprising anchor supports (24) associated with at least one of the top of said building panel and the bottom of said building panel, said anchor supports supporting an upper plate and / or a lower plate from said inner layer. Resin-based fiber-reinforced composite structural construction panel according to any one of claims 1, 2, 3, 4, 5, 6, 7, or 8, further comprising a support bracket. mounted to said building panel in association with the upper part of said building panel, said support bracket comprising a support panel (176, 176A, 176B) adapted to support at least one of (i) an edge portion of an overlapping floor adjacent said building panel, whose edge portion overlaps said support panel, (ii) an edge portion of a structural slab next to the building panel garage floor; and (iii) bricks as an outwardly laid layer in a construction in which said support bracket is being used, said support panel optionally comprising a brick support panel adapted to support bricks as an outwardly placed layer in a construction in which said support bracket is being used. Resin-fiber reinforced composite structural construction panel according to claim 5, characterized in that said rigid insulating foam has a density of from about 16 kg / m3 to about 192 kg / m3, optionally from about 3 2 kg / m3 and approximately 128 kg / m3, and optionally filling the spaces between said inner layer and said outer layer, and between said respective structural reinforcement elements. Resin-fiber reinforced composite structural construction panel according to any one of claims 2, 3, 4, 5, 6, 7, 8, 9 or 10, characterized in that said one or more elements of structural reinforcement comprises straight structural reinforcement elements when said building panel is in a vertical orientation, further comprising structural reinforcement elements extending transversely between those of said straight structural reinforcement elements, optionally where said structural reinforcement elements are extend transversely and said collectively straight reinforcing elements collectively define regular closed geometric shapes, which generally extend continuously between said inner layer and said outer layer. Resin-based fiber reinforced composite structural construction panel according to any one of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or 11, characterized in that it comprises further rigid insulating foam elements in said structural building panel, (i) a first set of said foam elements having lengths thereof extending along the height of said building panel, widths thereof extending along the length of said building panel, and thicknesses thereof less than its widths extending along the thickness of said building panel, (ii) a second set of said foam elements having lengths thereof extending along the height of said building panel whose widths extend along the thickness of said parent construction level, and thicknesses thereof less than respective widths extending along the length of said construction panel, the widths of the second set of said foam elements being greater than the thickness of the first set of said construction elements. foam, those of said second set of said foam elements being spaced apart by those of said first set of said foam elements. Resin-fiber reinforced composite structural construction panel according to claim 12, characterized in that said inner layer extends over said inner surfaces of said first set of said foam elements and over inner surfaces of said foam. said second set of foam elements such that both the first set of foam elements and the second set of foam elements are placed between said inner layer and said outer layer. Resin-based fiber reinforced composite structural construction panel according to claim 12 or 13, characterized in that said inner layer extends outwardly into such a construction adjacent to a foam element. from the first set to an innermost portion of a foam element of the second set, a distance of from about 7.6 cm to about 15.2 cm. Resin-fiber reinforced composite structural construction panel according to any one of claims 12, 13 or 14, characterized in that the foam elements of at least one of said first and second foam element assemblies being encased in resin impregnated fibrous wrapping layers, said resin impregnated wrapping layers optionally having a nominal thickness between about 0.076 cm and about 0.38 cm, optionally wherein said foam elements comprise closed cell having densities between about 16 kg / m3 and approximately 192 kg / m3. Resin-fiber-reinforced composite structural construction panel according to any one of claims 1, 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14 or 15, characterized in that said structural construction panel comprises a fiber reinforced pultruded structure, said pultruded structure in vertical use orientation having a vertical crush strength of at least approximately 2 97 5 kg per linear meter. in length of said building panel. Resin-fiber reinforced composite structural construction panel according to claim 16, characterized in that said pins are integral elements of said pultruded structure. Resin-based fiber reinforced composite structural construction panel according to any one of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 , 15, 16 or 17, characterized in that (a) a first set of fiber reinforced pultruded blocks have lengths thereof extending along the height of said building panel, widths of said first set of blocks extending extending along the length of said building panel, and thickness of said first set of blocks, being less than respective widths extending along the thickness of said building panel; and (b) a second set of fiber reinforced pultruded blocks having end walls (126, 130) and members (128) extending between said end walls, and lengths of said pultruded blocks extending along the end. height of said building panel, widths of said second set of blocks extending along the thickness of said building panel, and thicknesses of said second set of blocks less than the respective widths of said second set of blocks extending along the length of said building panel, the widths of the second set of pultruded blocks being greater than the thicknesses of said first set of said pultruded blocks, those of said second set of pultruded blocks being spaced apart by those of said first set of pultruded blocks, said blocks of said first and second sets of pultruded blocks being in an adjacent relationship to each other and defining a generally continuous outer surface of such assembly of such first and second sets of pultruded blocks, an interior surface (57) collectively defined by said first set of pultruded blocks being interrupted along the length of said building panel by said pultruded blocks of said second set of blocks. Resin-fiber reinforced composite structural construction panel according to Claim 18, characterized in that said pultruded blocks of said second assembly comprise a reinforcement web (238) disposed from both said walls. (126, 130) and extending between said first and second members. Resin-based fiber-reinforced composite structural panel according to claim 18 or 19, further comprising a fiber-reinforced inner polymeric layer mounted on said first and second pultruded block assemblies. for consolidating said pultruded blocks of said first and second assemblies together on the inner surface of said building panel. Resin-based fiber-reinforced composite structural construction panel according to any one of claims 18, 19 or 20, further comprising an outer or adjacent fiber-reinforced polymeric layer (36); said first and second sets of pultruded blocks on or adjacent to the generally continuous outer surface so as to transpose between said respective pultruded blocks. Resin-based fiber reinforced composite structural construction panel according to any one of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 , 15, 16, 17, 18, 19, 20 or 21, characterized in that said pins have inwardly facing end panels (130) adapted to face inwardly inwardly of such a construction, said paneling panels. end (130) optionally being disposed from said inner layer between approximately 2.54 cm and approximately 15.2 cm, the inner sheet material (119) being mounted to said end panels before said building panel is installed in such a construction to thereby close the casually rising view visibility channels (131), and one or more utility passes in one or more of the channels (131), whereby the utilities in the channels are hidden. casual elevation view visibility. Resin-fiber-reinforced composite structural construction panel according to any one of claims 2, 3, 4, 5, 6, 7, 8, 9, 10,11, 12, 13, 14, 15 , 16, 17, 18, 19, 20, 21 OR 22, characterized in that said fiber-reinforced polymeric structural building panel including said fiber-reinforced outer layer, said fiber-reinforced inner layer, said fiber reinforcing members. structural reinforcement, and said pins, comprise said pultruded construction panel. Resin-based fiber-reinforced composite structural wall section as a building construction element, characterized in that it is made of at least the first and second structural wall panels of claims 1, 2, 3, 4. , 5, 6, 7, 8, 9, 10, 11, 12, 13,14, 15, 16, 17, 18, 19, 20, 21, 22 or 23, joined together. A composite structural wall section according to claim 24, further comprising at least one of a fiber-resin composite top plate and a fiber-resin composite bottom plate optionally a pultruded lower plate. and wherein said lower plate is at least approximately 0.46 cm thick. Foundation below the standard load-bearing type as a building construction element comprising at least first and second vertical wall panels of claims 1, 2, 3, 4,5, 6, 18 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24 or 25, wherein said wall panels comprise foundation wall panels joined together. , and extending upwardly from a stable base, optionally upwardly from a fabricated base defining one or more load bearing foundation walls. Foundation according to claim 26, characterized in that it further comprises a support bracket mounted to said foundation wall provided in association with the upper part of said foundation wall, said support bracket comprising a panel. a bearing adapted to support at least one of (i) an edge portion of an overlapping floor adjacent said respective foundation wall, whose edge portion overlaps said holding panel, (ii) an edge portion of a slab next to said foundation wall, and (iii) a brick tablet as a layer laid out in a building. Construction, characterized in that a vertical wall is made of at least the first and second vertical wall panels of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13. , 14, 15, 16, 17, 18, 19, 20,21, 22, 23, 24, 25, 26 or 27. 29. Construction, characterized in that it comprises: (a) a load bearing foundation, said load bearing foundation having a lower portion thereof below the standard type, and an upper portion, and comprising (i) a load bearing base, and (ii) a load bearing foundation wall overlapping said base and interfacing with said base, optionally through a deformed transposition material, and applying direct downward force. said base, said foundation wall having an upper part, a lower part, and a length, and (b) a structure above the standard type supported by load bearing foundation, said base comprising a seated fabricated base, a said load bearing foundation wall comprising a plurality of vertical foundation wall panels connected to one another side by side, said wall panel upwardly extending foundation frame from locations on or adjacent to said base and comprising a wall panel as of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26 OR 27. Construction according to Claim 29, characterized in that it further comprises a support bracket mounted to said foundation wall in association with the upper part of said foundation wall, said support bracket comprising a support panel. (176, 176A, 176B) adapted to support at least one of (i) an edge portion of an overlapping floor adjacent said building panel, whose edge portion overlaps said support panel, (ii) a edge portion of a structural slab next to said foundation wall, and (iii) bricks as a layer laid out in a construction in which said support bracket is being used. Construction according to either of claims 29 or 30, characterized in that the first and second foundation wall panels collectively define adjacent portions of said foundation wall, and said first and second foundation wall panels are connected. each other in a joint where said first and second foundation wall panels meet in relation to edge to edge. Construction according to any one of claims 29, 30 or 31, characterized in that said construction further comprises a concrete slab floor overlapping a portion of said upper plate and limiting said interior surface (25) of said construction. said foundation wall. Construction according to any one of claims 29, 30, 31 or 32, characterized in that it further comprises a support beam extending through an open gap between the first and second portions of said foundation, said beam. support being placed at an elevation near the top of said foundation, and being supported by at least the first and second of said various foundation wall panels, said support beam being constructed of a material selected from the group comprising It consists of natural wood, manufactured wood products, metal I-beams, and fiber-reinforced plastic composite beams. 34 Construction according to any one of claims 30, 31, 32 or 33, characterized in that said construction further comprises a concrete slab floor overlapping a portion of said lower plate and limiting said inner layer of at least one portion. said foundation wall near the bottom of said foundation wall. Construction according to any one of claims 29, 30, 31, 32, 33 or 34, characterized in that said foundation wall further comprises at least one of a fiber-resin composite top plate and a bottom plate of fiber-resin compound, optionally a pultruded lower plate and where such a lower plate is at least about 0.46 cm thick. 36. Construction constructed of no structural use of concrete other than floor slabs, characterized in that it comprises: (a) a load bearing foundation, said load bearing foundation having a lower portion thereof below the standard type, and a higher one, and comprising (i) a load bearing base devoid of concrete structural use, (ii) a load bearing wall of Claim 29, which overlaps said base and applies downwardly directed force to said base, said load bearing wall being devoid of structural use of concrete. 37. Construction, characterized in that it comprises: a load bearing foundation; and a vertical wall according to Claim 28 supported by said load bearing foundation. Construction according to any one of claims 29, 30, 31, 32, 33, 34, 35, 36 or 37, characterized in that said foundation comprises a base and a foundation wall supported from said base, said foundation wall having a length and thickness, further comprising a bottom plate mounted to the bottom of said foundation wall, said bottom plate extending along the length of said foundation wall and extending along the thickness of said foundation wall, and optionally extending into said construction beyond said inner layer, said bottom plate optionally comprising a composition selected from the group consisting of a natural treated wood bottom plate, a plate manufactured wood bottom, a composite fiber-reinforced polymeric bottom plate, and a pultruded bottom plate. Construction according to Claim 38, characterized in that said construction further comprises a concrete slab floor which overlaps a portion of said lower plate and limits an internal surface of said foundation wall. Construction according to Claim 37, characterized in that said vertical wall is a wall above the standard type. 41. Construction, characterized in that it comprises: (a) a load bearing wall having an upper part and a lower part, an upper plate optionally defining the upper part of said load bearing wall; and (b) a load bearing wall-supported building floor, said Construction floor having an upper portion, and comprising a floor structure comprising floor support elements, said floor support elements being supported, from said load bearing wall at locations on said support elements which are below the top of said load bearing wall. Construction according to Claim 41, characterized in that it further comprises a support bracket at the top of said load bearing wall and extending below the top of said load bearing wall to a panel. floor support (176, 176A, 176B), said floor support panel supporting said floor support elements at such locations in such floor support elements that are below the top of said load bearing wall. Construction according to Claim 41 or 42, characterized in that said load bearing wall comprises structural concrete extending upwards from a base. Construction according to Claim 41 or 42, characterized in that said load bearing wall comprises a structural wall extending upwards from a base, and wherein said load bearing wall is devoid of structural use of concrete. Construction according to any one of claims 40, 41, 42, 43 or 44, characterized in that the top of the floor is within 10 cm of vertical measurement of the top of the load bearing wall, and where optionally the upper floor generally corresponds in height to the upper part of the load bearing wall. Construction according to any one of claims 41, 42, 43, 44 or 45, characterized in that said floor structure comprises said floor support elements plus finishing base, said floor structure having a height between the lower parts of said supporting elements and the upper part of said floor structure, and where the upper part of said floor structure is at an elevation that is not higher than a height that is defined above said wall of load bearing, and which is less than once the height of said floor structure. Construction according to any one of claims 41, 42, 43, 44, 45 or 46, characterized in that said load bearing wall has an inner surface and an outer surface, said floor support elements having ends placed into the outer surface of said load bearing wall. Construction according to any one of claims 41, 42, 43, 44, 45, 46 or 47, characterized in that said construction further comprises one or more straight upper walls and a ceiling, supported above said construction floor. . Construction according to any one of claims 41, 42, 43, 44, 45, 46, 47 or 48, characterized in that said construction floor is supported by said load bearing wall via a support bracket. said support bracket comprising a base panel (178, 178A) configured to be placed in a vertical orientation against said load bearing wall, an upper panel fixed to said base panel near an upper part of said panel base, a retaining panel extending downwardly from said upper panel, and a support panel extending outwardly from said base panel to a distal edge of said support panel. Construction according to any one of claims 41, 42, 43, 44, 45, 46, 47, 48 or 49, characterized in that said load bearing wall comprises a fiber-reinforced external polymeric layer which defines a outward facing surface of said building panel when said building panel is being used in a building wall, a fiber reinforced inner polymeric layer, said inner layer generally defining an inwardly facing surface (25) of said building wall load bearing, and various structural bearing pins extending into the inwardly facing surface (25), and channels between said pins, such channels being sized and configured to receive utility passages, where the interior sheet material ( 129) can be placed over said pins thereby concealing user passages elevation view visibility library. Construction according to any one of claims 41, 42, 43, 44, 45, 46, 47, 48, 49 or 50, characterized in that said load-bearing wall comprises a pultruded load-bearing structure which in combination defines said inner layer, said outer layer, and said pins. Construction according to any one of claims 41, 42, 43, 44, 45, 46, 47, 48, 49, 50 or 51, further comprising a pultruded cover on the upper part of said wall and extends between said inner layer and inwardly placed end panels (130) of said pins. 53. Fiber reinforced polymer composite structural support support (48, 188) adapted to be mounted to an upper part of a foundation wall, characterized in that said support support comprises: (a) a panel of base (178, 178A) configured to be placed in a vertical orientation against a vertical foundation wall, said base panel having a length, an upper portion, a lower portion, and a height between the upper portion and the lower portion; (b) an upper panel (182) having a length thereof and is attached to said base panel near the top of said base panel, and extending said base panel transversely to a distal edge thereof; (c) a retaining panel (184) having a length extending along the height of said upper panel, said retaining panel further having an upper part, a lower part, and a height between the upper part and lower, said retaining panel extending downwardly from near the distal edge of said upper panel; (d) a support panel (176, 176A) having a length extending along the length of said base panel and extending outwardly from an edge near said support panel, and away from the said base panel to a distal edge of said support panel; and (e) a shoring panel (180) extending from the distal edge of said support panel downward to a junction with said base panel at a downward angle providing support for said support panel (176). 176A) from said base panel (178) sufficient such that said support panel and said shoring panel (180) collectively hold said support panel in an orientation that approximates a stay orientation in use, when said support bracket is mounted on such a foundation wall, with such a base panel against said foundation wall, and a downwardly directed projecting load is placed on said support panel (176). Support bracket according to Claim 53, characterized in that said retaining panel (184) defines a second base panel (178B), further comprising a second support panel (176B) extending along the base. length of said second support panel (178B) and extending outwardly from an edge near said second base panel to a distal edge of said second support panel and a second shoring panel (180B) extending from the distal edge of said second support panel down to a junction with said second base panel at a downward angle providing support for said second support panel (176B) from said second base panel sufficiently said second support panel and said second shoring panel (180B) collectively, maintaining said second support panel in an orientation that approximates a permanence orientation in use when said support bracket is mounted on such foundation wall, with such base panel against said foundation wall, and a load The directed downward direction is placed on said second support panel (176B). Supporting bracket according to Claim 53 or 54, characterized in that each of said base panel, said upper panel, said retaining panel, said supporting panel, and said shoring panel comprises polymeric panels. resin impregnated fiberglass reinforced, optionally where the nominal thickness of said panels is between about 0.76 mm thick and about 3.8 mm thick. Construction structure according to Claim 27, further comprising a load selected from the group consisting of (i) a structural slab having an edge thereof next to said foundation wall, (ii) ) brick facade, and (iii) floor beam ends adjacent an inner surface of said foundation wall, said load overlapping, and loading, said support panel of said support bracket. Building structure according to Claim 56, characterized in that said support panel extends away from said foundation wall from locations close to the inwardly facing surface of said foundation wall and is adapted for supporting one of (i) a structural slab having an edge thereof next to said foundation wall, and (ii) ends of floor locks adjacent an inner surface of said foundation wall, said support bracket further comprising a second support panel extending from locations proximate to the outwardly facing surface of said foundation wall and adapted to support one of (iii) a structural slab having an edge portion thereof next to said base wall. (iv) bricks as a load placed to out on said support bracket. 58. Load distribution support and load support shim having an upper and lower part, a length and width, and a thickness between the upper and lower part, characterized in that said shim is be adapted to be used as an interface base between an underlying natural base and an overlay constructed structure, said support shim comprising several fiber-reinforced polymeric layers, said shim having dimensions of at least 0.30 meters in length and 0.30 meters wide, and at least approximately 2.5 cm thick, said support wedge further having a load bearing capacity of at least 4879 kg / m2 as defined by length and width. Load bearing support shoe according to Claim 58, characterized in that said support shoe has a thickness of at least 7.5 cm and a load bearing capacity of at least 1,361 kg / m2. Load-bearing support shim according to Claim 58 or 59, characterized in that the layers are stacked on top of each other, with the main surfaces of said layers generally facing towards the top and bottom of the housing. said supporting shim, so that relatively underlying layers support relatively overlying layers. Load-bearing support pad according to any one of claims 58, 59 or 60, characterized in that the layers represent a forward and back folding pattern where each successor layer overlaps the previous layer. Load-bearing support pad according to any one of claims 58, 59 or 60, characterized in that the layers are wrapped around one or more core layers. 63 Load-bearing support pad according to any one of claims 58 or 59, characterized in that the support pad is a pultruded product where respective layers are represented in spaced upper and lower webs (34, 36) of the pultruded pad, and where the upper and lower frames are connected to each other by connecting frames (35). A load-bearing support shoe according to any one of claims 58, 59, 60, 61, 62 or 63, characterized in that the thickness of said support shoe is not more than half the magnitude of the lower one. of the length or width of said support shim. 65. Built structure designed on an underlying base, characterized in that said constructed structure comprises: (a) a load bearing foundation having a lower portion thereof below the standard type; and (b) a supported structure having a height and is supported by said load bearing foundation, said load bearing foundation comprising a fabricated base, and foundation support structure extending upwardly from the said base, and supporting said supported structure, said manufactured base comprising one or more discrete structural wedges of claims 58, 59, 60 or 61, said supporting structure overlapping and applying weight to and being supported by said base. support shim on the shim top. 66. Built structure according to Claim 65, characterized in that said foundation supporting structure comprises one or more supporting columns, said supporting columns having generally enclosed structural sidewalls supporting the weight of an overlapping portion. of the sustained structure, said structural sidewall of said support column defining a cross section of said column near the top of said column further comprising a structural cover overlapping said support column at the top of said support column. said structural covering comprising a structural top panel, and a structural edge extending downwardly from said structural top panel, said structural top panel distributing the weight of the overlap portion to the above structure of the standard type in order to equally distribute weight around the cross section of the underlying support column, and transfer the weight distributed to said support column. 67. Built structure according to claim 66, characterized in that the sustained structure comprises a beam extending generally horizontally, and which applies a load to said column, said beam which is selected from the group consisting of in natural wood beams, manufactured wood beams, fiber reinforced polymer beams, fiber reinforced pultruded beams, and structural metal beams. Constructed structure according to any one of claims 65, 66 or 67, characterized in that said sustained structure comprises one of a closed portion of a building and an unclosed structure joining a closed building structure. 69. A method of producing a structurally constructed panel comprising: (a) depositing a first fiber rich layer onto a support, the first fiber rich layer having a width defined by the first and second side edges, a direction in length, and an upper surface; (b) placing foam blocks in the first layer, lengths of the foam blocks extending generally between the first and second side edges of the first fiber rich layer; (c) depositing a second fiber rich layer over the combination of the first fiber rich layer and the foam blocks to thereby develop an uncured precursor for the building panel; and (d) curing the uncured precursor to the building panel to thereby produce a generally rigid structural building panel. Method for producing a structural building panel according to Claim 69, characterized in that the first fiber rich layer is a generally endless resin impregnated fiberglass layer impregnated with a first curable liquid resin, the first resin-impregnated layer having a width defined by the first and second side edges of the first resin-impregnated layer, a length direction, and an upper surface, where the foam blocks (32) are placed at spaced locations along the length of the first resin impregnated layer, spaces (84) being placed between those of the foam blocks (32), by which the upper and lateral surfaces of the foam blocks are exposed, the method further comprising depositing a fiber-impregnated fiberglass weave layer. usually endless resin (50) impregnates with a curable liquid resin, on the combination of the first resin-impregnated layer and the foam blocks, including weaving the weave layer (50) into and out of the spaces (84) between the foam blocks, space boundaries then being defined by the weave layer (50), placing additional foam blocks (32) in the spaces (84) and over portions of the weave layer (50) to thereby define a generally consistent thickness of a resulting structure along both a resulting frame length and a resulting frame width, and a generally flat upper surface of the resulting frame, and depositing the second resin-impregnated fiberglass layer onto the upper surface of the resulting frame, to thereby develop the precursor. cured to the building panel. A method according to Claim 70, further comprising manufacturing one of the first, second, and third layers by passing a fiberglass layer between a pair of rollers which together define a piece therebetween, and maintain a pool of the respective resin liquid in the piece so that the fiberglass layer passes into the liquid resin pool before it passes through the piece to thereby produce the respective resin impregnated fiberglass layer, and wherein the third resin-impregnated layer optionally covers substantially the entire width of the resulting structure. Method according to Claim 70 or 71, further comprising, after both the second and third resin-impregnated fiberglass layers have been deposited on the combination of the weave layer and the foam blocks. and before curing the resulting structure, apply prefabricated pins (123) to the third resin-impregnated fiberglass layer with sufficient proximity of contact between the third layer and the pins so that subsequent curing binds the pins. sufficiently so that the pins contribute to a significant increase in the bending strength of the resulting structural construction panel. 73. A method of fabricating a structural building panel, comprising: (a) filling an open mold comprising (i) placing optionally resin-coated structural reinforcement elements into spaced female recesses (302) (ii) extracting an inner layer (334) of reinforcing fiber fabric over the female-type molding element and consequently over the reinforcing elements to cover the structural reinforcing elements. (iii) placing foam blocks, pre-wrapped with layers (314) of reinforcing fibers, and optionally resin coated, in edge-to-edge relationship, over the top of the fabric layer (334) so as to covering the layer (334) on the female-type molding element, and (iv) extracting an outer layer (335) of reinforcing fiber fabric over the pre-wrapped foam blocks to cover the foam blocks, and op. apply resin to the outer fabric (335) while the mold is open; (b) close the mold; and (c) extracting a vacuum into the mold to evacuate air from the mold and filling air-evacuated spaces with a cure-type liquid resin. 74. A method of constructing a structure comprising a construction having a general outer perimeter, or a building complement located outside such a general outer perimeter, according to a structure plan, comprising: (a) excavating a hole to establish a natural foundation on which the structure is to be built; (b) establish configuration locations where vertical walls or other frame supports are to be erected; (c) establishing a fabricated base, optionally a fiber reinforced polymeric base, along the planned locations of the supports; (d) placing as prefabricated load bearing supports one or more fiber reinforced polymeric construction panels according to any one of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26 OR 27, or fiber reinforced polymeric structural columns on the fabricated base; (e) connecting respective prefabricated wall panels or fiber-reinforced polymeric structural columns to each other to the extent required by the structure plane thereby developing spaced load bearing walls or structural column supports, and (f) erecting overlapping structure over load bearing walls or spaced structural columns. Method according to claim 74, characterized in that the overlapping structure comprises a wall overlap above the standard type and supported by the foundation wall. Method according to claim 74 or 75, characterized in that it includes using, as the fabricated base, aggregate stone or one or more fiber reinforced polymer shims. A method according to claim 74 or 75, further comprising establishing the fabricated base as a concrete base, placing a deformable and curable bonding material on the concrete base, and placing the pre-formed wall panels. fabricated on the concrete base, on the bonding material such that at least a portion of the bonding material is between the concrete base and the prefabricated wall panels. Method according to any one of claims 74, 75, 76 or 77, characterized in that the overlapping support structure comprises one or more support columns, the method further comprising cutting off one or more support columns, as required, at a desired height, so to define one or more supports individually comprising a base shim and at least one support column, each column having a column top, the foundation collectively comprising a combination of one or more more base shims and one or more supports. A method according to claim 78, further comprising installing structural covers overlapping the support columns on the upper parts of the support columns and whose structural covers interface between the support columns and the structural elements above the ceiling. default type. Method according to any one of claims 75, 76, 77, 78 or 79, characterized in that the method comprises adding the elements above the standard type so that the structural elements of the elements above the standard type extend below the standard type. standard. Method according to any one of claims 78, 79 or 80, characterized in that the totalities of all the supporting columns are below the standard type, and are hidden from view after further filling, and optionally where the columns of Supporting structures comprise structural fiberglass-reinforced polymeric structures that provide structural support to the complement, optionally where the covers comprise structural fiberglass-reinforced polymeric structures that diffuse overlapping loads to column sidewalls. Method according to any one of claims 74, 75, 76 or 77, characterized in that the wall panels of claims 1, 2, 3, 4, 5 are used as prefabricated load bearing supports. 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22.23, 24, 25, 26 or 27.