BRPI0820789B1 - Fiber-reinforced polymeric structural building panel and structural outer wall in a building - Google Patents

Abstract

fiber-reinforced polymeric structural building panel and structural outer wall in a building methods of fabricating wall panels by generally continuous pultrusion of a wall panel profile comprising inner and outer layer, and spaced reinforcing webs and / or foam extending between the inner and outer layer, optionally plumbs extending inwardly from the inner layer away from the outer layer. The thus continuously pultruded wall panel optionally has male and female edges. The wall panel is periodically cut to wall panel height, thereby creating a continuous flow of cut wall panels. The panels are advanced through a corner indexing station, and indexed at right angles while maintaining the orientation of the panels. the wall panels leave an indexing station, edge to edge. Resin is applied to the facing edges of adjacent wall panels. adjacent wall panels are joined together at the confronting edges to make a generally continuous wall panel. The thus joined wall panel is cut to desired lengths. The resulting wall panel can provide sturdy, otherwise weatherproof and weatherproof building systems without the structural use of concrete except for floor slabs.

Description

This invention refers to building systems that largely replace concrete, be it ready-mix concrete or prefabricated concrete blocks, or other prefabricated concrete products, in construction projects. In general, the invention replaces concrete in low-level frost walls and foundation walls, in high-level walls and in concrete bases, and in pillar blocks. Such concrete structures are replaced, in the invention, with pultruded structures, and structures otherwise manufactured, such structures based on layers based on fibers, impregnated with resin, with composite materials, also known as fiber-reinforced polymer materials ( FRP). Such structures typically include thermally insulating foams, and optionally include regularly spaced uprights, especially in vertical, lower-level wall sections. Thus, with the exception of flat concrete work such as concrete floors, the 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 forms, for example, 1,83.6 meters (4 - 8 feet) high, are brought in, assembled in place, and raised on top of the base. Ready-mix concrete is then poured from a

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2/103 ready mix, inside the molds and allowed to consolidate and cure, in order to create the foundation walls, which can be a wall with freeze protection if no basement is planned.

In the alternative, and still dealing with construction of conventional foundation, the vertical portion of the foundation wall can be built using prefabricated concrete masonry units (cmu's) and mortar, typically supported by conventional poured concrete bases.

In yet another conventional type of construction, frost walls or foundation walls are constructed using concrete blocks covered with mortar.

In any case, in such conventional structures, when the concrete is being finished on the tops of the formwork, or in the upper row of concrete blocks, dowels or other fastening piles are partially embedded in the concrete that hardens or mortar in such a way that the piles extend from the top of the foundation wall and, when the poured concrete, or mortar, has hardened, such piles serve as clamping piles, for example, to mount an upper sheet, also known as a low beam, on the top of the wall of foundation, thereby fixing the building structure overlying the foundation or protecting against freezing. When concrete hardens on a conventionally dumped foundation wall, the molds are removed, for example, 1-2 days after the ready mix concrete is poured into the molds, and a wood, or wood product, or other top plate is fixed on top of the wall

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3/103 concrete foundation, using the piles that are embedded in the concrete on top of the concrete foundation wall. A similar waiting time is necessary with a concrete block wall, covered with mortar, before the upper plate is fixed on the top of the wall thus manufactured.

The poured concrete wall construction process, noted above, and the concrete block construction process, require a substantial amount of concrete materials, investment in formwork, substantial site work and several days of time to fabricate the foundation of the building on which the ground floor of the building can then be erected. If construction is done in winter in a northern climate, concrete is typically heated, incurring an associated cost, to facilitate concrete curing.

In addition, such a resulting concrete foundation wall is water permeable and thus must be waterproofed although, even after a conventional waterproofing coating has been applied to make the foundation wall waterproof, water leakage through such a concrete foundation wall , whether ready-mixed wall or concrete block wall, is more properly common. In addition, a concrete wall is a good thermal conductor, and thus must be insulated to prevent heat loss through conduction through the concrete to the ground or other landfill that surrounds the building. However, the effect of such insulation is limited because only relatively thin insulation materials are commonly used with concrete wall construction.

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4/103 underground.

Furthermore, if the level of the building inside the concrete wall must be enabled, be it a level below, for example, foundation wall, or level above, then plummeting, for example, 2x4 plumbs or 2x6 plumbs are typically fixed to the plaster wall. concrete as a substrate that facilitates the installation of insulation and utilities, and serves as a substrate for the installation of a finished interior wall surface such as stone sheets or cladding. Such devastation consumes interior space within the building as well as additional time and money for its installation.

The total time required to build such a building foundation can be reduced by fabricating the concrete walls off site and lifting the walls manufactured on site, on site, using a crane. However, each such wall element must be custom-designed, increasing the cost; and relatively heavy-duty mechanical lifting equipment, for example, the crane, must be brought to the construction site, and is also a cost item.

Having the foundation walls installed in a timely manner, to accommodate the timely delivery of built homes and other buildings to buyers, is a significant problem in the construction business. There are many reasons why foundations are not installed according to a planned schedule. Such a substantial problem is related to climatic conditions. Climatic conditions in northern climates may be below freezing for several months of the year, which

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5/103 makes it difficult to install foundations. In addition, installation of quality concrete foundation walls requires specialized work, as well as specialized subcontractors, including specialized work by subcontractors.

Another known method of building structural walls is through the use of Insulated Concrete Formwork (ICF) walls. In such a construction, isolated forms are erected on bases and receive concrete poured from ready mix. After curing, the external portions of the molds are left as a thermal insulation layer between the concrete and at least one of the surfaces, internal and external, of the resulting wall. Although ICF walls offer a relatively higher level of thermal insulation than a conventional, non-insulated, conventional wall, an ICF wall is typically more expensive than a simple concrete wall, and is more difficult to finish than a wall of concrete. simple concrete either by 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 deterioration, and corresponding decomposition of the wood. Such treated wood is well known and is conventionally available. Such foundation walls typically include at least one bottom plate, and can be wrapped in plastic and then mounted on an aggregate stone base. Wooden foundations have some advantages, including allowing a manufacturer of such wooden foundations to manufacture sections of such a wall in the

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6/103 the closed and controlled environment of a manufacturing facility, so that the sale and delivery of such a product is generally insensitive to weather conditions. In addition, wood offers advantageous speed in building a building, and is relatively light compared to concrete.

However, wooden foundations are not well received by the consuming public, since the public does not perceive quality in a building where wood is used in a lower level application.

There is a need in the construction industry for relatively light structural building panels, for example, generally continuous wall panels of any desirable length up to a maximum length per panel, selectable in length, height, and thickness, whose panels structural, can be used in applications where concrete is conventionally used in residential, light commercial, and light industrial construction, and whose structural building panels are strong enough to withstand the compression loads and side loads that are typically imposed on concrete walls in such building structures.

There is also no need for walls that have superior moisture and water barrier properties.

There is also a need for walls that can be installed in order to be ready to support the overlying building structure in a relatively shorter period of time.

There is still a need for walls that can be

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7/103 installed with a lower life cycle cost. There is also a need for accessories that support another structure that rests on such wall sections, and that serve as connectors between such wall sections and such another structure.

There is also a need for such walls that meet consumer expectations, both in terms of function and in terms of perceived quality.

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

SUMMARY OF THE INVENTION

This invention represents wall panels, and methods of making wall panels for a sturdy, waterproof building system that provides wall, ceiling, and / or floor building panels and corresponding walls and wall sections, ceilings and ceiling sections, and floors and floor sections. The walls, considered in a vertical orientation, have not only resistance to vertical compression but also resistance to horizontal flexion, sufficient so that the wall system can be used in building structures applications above ground and below ground, including applications where such wall systems are exposed to intense wind and other weather, such as hurricanes, tornadoes, and the like. Such walls can replace concrete, and can meet the required strength specifications for use in corresponding individual family, light commercial, and light industrial applications.

Similarly, ceilings and floors can be made with

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8/103 building panels of the invention having sufficient vertical and horizontal load capacities to support the loads typically imposed on the corresponding ceilings and floors in the construction of individual, light commercial and light industrial family residence.

A wall structure of the invention has an external waterproof layer, comprised of reinforcement fibers embedded in polymeric resin, and defining the surface facing away from the panel, an internal waterproof layer comprised of fiberglass. reinforcement embedded in polymeric resin and defining the surface facing inwards towards the panel, and at least one of (i) one or more strands of structural reinforcement, spaced from each other, and extending between the inner layer and the outer layer, and (ii) one or more foam sheets filling the spaces between the inner and outer layers. Several structural, polymeric, fiber-reinforced reinforcement members can extend the full height of the raised wall panel, and can extend from locations on the inner surface or close to the inner surface of the outer layer to locations on the inner surface or close to the internal surface of the wall structure, at locations spaced along the length of the wall panel.

The inner layer, the outer layer, and the reinforcement members are part of a resinous structure, reinforced with fiber, optionally pultruded.

Optionally, a reinforcement plumb is fixed, or included in the fabricated structure, and extends towards the inside of the building beyond what is otherwise the internal wall of the building panel / wall panel. O

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9/103 plumb can originate in the inner layer or the outer layer of the pultruded structure.

The spaces between some of the structural reinforcement members, and between the inner and outer layers, are optionally filled with rigid insulating foam material such as polyurethane foam or polystyrene foam, phenolic foam, or polyisocyanurate foam.

The structural reinforcement members can be integral with the inner and outer layers, so that the reinforcing elements of the structural reinforcement members, which extend between the inner and outer layers, work in a capacity similar to that of a beam frame. I, and associated portions of the inner and outer layers, function in capacities similar to the functioning of the flanges of such an I-beam. The effect of total I-beam provides, in a vertical wall panel, or wall, not only resistance to horizontal bending but also resistance to vertical compression, sufficient to support not only vertical compressive loads but also lateral loads, starting from which the building walls are designed, and can provide such sufficient levels of strength in cross sections that are not superior to the cross sections of steel reinforced concrete walls that are conventionally used in such applications, while avoiding the drawbacks of concrete.

A foundation wall of the invention can be laid directly on a level bed of aggregated stone as a base. Alternatively, the foundation walls of the invention can be laid on a poured concrete base, with

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10/103 proper seal between the concrete base and a lower surface of the foundation wall, to accommodate deviations in the upper surface of such concrete base. In addition, it can be of elongated support blocks made with fiber-reinforced polymeric materials described here for use in making the building panels of the invention.

The invention encompasses that when buildings or other structures are constructed using the inventive structural elements and the members disclosed herein, such buildings, and other structures, as well as respective substructures and subassemblies that are related to such buildings and structures, are inventive.

The invention generally comprises building panels, and methods of manufacturing the building panels either as defined length panels and defined height panels, in controlled environment manufacturing facilities. Considering a vertical orientation, such a building panel has a defined length, a defined thickness, and a defined height. A continuously pultruded panel can be cut at any desired height along the length of the pultruded product and the panels can be joined and / or cut to provide any desired panel lengths at the manufacturing facility. Thus, walls and wall panels can be delivered from the manufacturing facility in different lengths and / or heights. In addition, the panels can be cut as needed at the construction site such as to create unfinished openings for windows and / or doors.

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10/113

An exemplary method for manufacturing such building panels comprises continuous pultrusion of panels having defined standard panel lengths and thicknesses, cutting the panels at desired panel heights, and joining adjacent panels at panel edges and / or cutting panels or panel assemblies to obtain the desired panel lengths. Thermal insulation foam can be incorporated into the pultruded structure, either during the manufacture of the pultrusion product, or after the pultrusion product has been cured, dimensionally consolidated.

The panels can be formed with or without plumbs that extend, starting from the inner layer, in the opposite direction to the outer layer. A plumb leg can be aligned with one of the structural reinforcement members. Under load from an overlying building, panels with plumbs are deflected out of the building towards the landfill. When installed on a fabricated base, a panel of the invention can vary in height by a factor of no more than 6.4 mm (0.25 inches) over a distance of 12.7 m (40 feet). On a 2.7 m (9 ft) high wall, the load distribution at the base varies by no more than 25% across any 3.05 m (10 ft) length of a foundation wall of the invention.

For example, prefabricated foam blocks can be fed in the pultrusion process together with the resin and the reinforcement fiber. The foam blocks can be pre-wrapped with fiberglass, or the foam and fiber blocks can be fed separately to the pultrusion process.

The invention further comprises methods of building

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12/103 buildings, comprising the construction of a building or building annex, the method comprising excavating a hole to establish a natural base on which the structure must be supported and built; establish design places where the vertical walls or other supports of the structure must be erected; establish a fabricated base, optionally a fiber-reinforced polymer base, pultruded, along the projected locations of the supports; placing prefabricated building panels, load-bearing, pultruded or other supports on the fabricated base; connect prefabricated wall panels or other supports mutually if and when so desired by developing load-bearing walls or other supports; and lifting the overlying structure over the load-bearing walls or other supports.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows a representative pictorial view, with parts removed, of a building foundation wall manufactured using the structures of the building system of the invention.

Figure 2 is a fragmented interior view of a section of one of the vertical wall structures shown in Figure 1.

Figure 3 is a cross-sectional view of the vertical wall structure taken at 3-3 of Figure 1.

Figure 4 is an external elevation representation of the vertical wall structure in Figure 3.

Figure 5 is a cross section in plan view of

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13/103 a portion of a foundation wall, below any layer of bricks, according to a second embodiment of the invention, with plumbs, and with a layer of stone plate fixed on the plumbs, and visualizing the base plate between the rock plate and a main projection section of the panel.

Figure 5A is a glass specification cross section, showing the uses of glass in an exemplary portion of a wall panel of the invention.

Figure 6 is a cross-sectional elevation view of the foundation wall structure illustrated in Figure 5, showing a layer of bricks.

Figure 6A is a cross section of elevation view as in Figure 6, without the brick layer, illustrating a different arrangement to support the overlying floor.

Figure 6B is an enlarged view of an upper portion of the structure shown in Figure 6A.

Figure 6C shows an enlarged elevation view of an upper portion of an alternative wall section, showing the attachment of the overlying building structure to the underlying wall structure.

Figure 6D is a representative elevation view, similar to Figure 6, showing the typical, relative lateral soil load on a wall.

Figure 6E is a graph showing the typical relative lateral load for three wall heights, each for three types of soil, usually showing load information, lateral force in table format.

Figure 7 is a fragmentary pictorial view

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14/103 showing a basement support block of the invention, supporting a conventional support pillar that supports an I-beam as in a basement location level below.

Figure 8A is a cross section of a layered support block illustrated in Figure 7, shown on an underlying earth or rock support base.

Figure 8B is a cross section of a pultruded support block illustrated in Figure 7, shown on an underlying earth or rock support base.

Figure 9 is a pictorial view of a square resin-fiber composite support pillar and resin-fiber composite cover, supported by a square resin-fiber composite support block of the invention.

Figure 10 is a pictorial view of a resin-fiber composite support post, square, and resin-fiber composite cover, of the invention, supported by an upward tapered support block, of resin- fiber, invention square.

Figure 11 is a pictorial view of a round, resin-fiber composite support pillar and resin-fiber composite cover, supported by a circular fiber-resin composite support block of the invention.

Figure 12 is a pictorial view of a rounded resin-fiber composite support pillar, and resin-fiber composite cover of the invention supported by an upward, circular tapered resin-fiber composite support.

Figure 13 is a pictorial line version of a

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15/103 optionally pultruded resin-fiber composite support support of the invention, which can be mounted on top of a foundation wall of the invention as illustrated in Figure 6.

Figure 13A is a pictorial line version of a resin-fiber composite H connector of the invention, which can be used to connect first and second wall panels in a straight line.

Figures 14 and 14A are pictorial views of the line drawing of the resin-fiber composite plate fixing brackets usable close to the upper and lower parts of the wall panels of the invention, for example, for fixing an upper plate and / or a lower plate on the wall panel, and to transfer lateral loads to the overlying floor.

Figure 14B is a pictorial drawing view of an alternative resin-fiber composite angle support that can be used in place of supports 14 and 14A.

Figure 15 is a pictorial line version of a garage and floor covering layer support, resin-fiber composite of the invention.

Figure 15A is a cross-sectional view of a joint in a wall of the invention, joining the first and second building panels of the invention using an H connector of Figure 13A.

Figure 16 shows a section of wall illustrating cross sections of plan view of fragmentary portions of first and second building panel, vertical, illustrating a first set of edge structures in

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16/103 two panels.

Figure 17 shows a wall section illustrating cross sections of plan view of the first and second building panels, verticals mutually joined in an end-to-end relationship at the edges of the panel, including integral uprights on the panels, and rock plate being applied over the plumbs.

Figures 18 and 19 show plan view cross sections of pultruded hollow panels and foam-filled panels of the invention.

Figure 20 is a plan view representative of an exemplary pultrusion and assembly process of the invention by which wall panels and wall sections can be manufactured at essentially any height and at any length.

Figure 21 is a cross section of a plan view representing a wall panel devoid of structural reinforcement members between the internal and external walls, in which foam blocks pre-wrapped with glass fibers are mounted on a prefabricated panel.

Figure 22 is a cross section of a plan view representative of a wall panel having plumbs, but no structural reinforcement members.

Figure 23 is a cross section of a representative plane view as in Figure 22, but with T-shaped reinforcements oriented upwards.

Figure 24 is an elevation view, from outside a building, of a section of a wall, generally illustrating the relative load distribution for an exemplary concrete wall section, and for a section of

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17/103 corresponding exemplary wall of the invention.

The invention is not limited in its application to the details of construction, or to the arrangement of the components presented in the following description or illustrated in the drawings. The invention is capable of other modalities or of being practiced or executed in several other ways. In addition, it should be understood that the terminology and phraseology used here are for the purpose of description and illustration and should not be considered as limiting. Similar reference numbers are used to indicate similar components.

DETAILED DESCRIPTION OF THE ILLUSTRATED MODALITIES

With reference to Figure 1, several foundation walls, interior and exterior 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 bottom plate 16, a vertical wall section 18, and an upper plate / threshold 20. As used here, wall panel ”14 can refer to a wall section 18 without the top plate 20 or bottom plate 16. Each vertical wall section 18 includes a main projection wall section 22, and vertically oriented reinforcement posts 23 affixed or integral with the main projection wall section, regularly spaced along the length of the wall section, and extending towards the inside surface of the main projection wall section. In the modality illustrated in Figure 1, fixing brackets 24 are mounted on the uprights in the upper and lower parts of the wall section, thus for

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18/103 assist in fixing the lower plate and the upper plate, and / or any other fixation, to the main projection portion of the vertical wall section.

A given plumb 23 (Figures 1-2 and 4-5) or 123 (Figures 3, 6, 6A, 6B and 17) has an end panel 130 and side panels 128 that extend from the main projection portion of the panel from wall to end panel 130.

As shown in Figure 1, conventional I-beams, for example, steel 26, are mounted on the wall sections, as needed, to support the overlying spans. Such steel I-life can be supported in one or more locations along the I-beam span, as needed, by conventional abutments, for example, steel, or by composite resin-fiber pillars 28 of the invention (Figures 1 and 8-12) and / or resin-fiber composite blocks 30 (Figures 1 and 8-12) of the invention. Additional support pillars can be used at the ends or adjacent to the ends of the I-beams as needed to meet the specific load-bearing requirements, individual to the building project. Fiberglass reinforced supports, or reinforcement posts 123 (Figures 3 and 5) or conventional supports, for example, steel, can be used to fix and / or support the I-beams in relation to the respective foundation wall panels using, for example, conventional steel dowels. Plumbs 23 are cut as needed to support the I-beam at the desired height. Multiple plumbs can be used side by side, as needed, to provide the ability to

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19/103 desired load support. Alternatively, beam receptacles can be manufactured on the foundation wall to receive the ends of the I-beam.

Referring now to Figures 3 and 5, the main projection portion 22 of the wall section is generally defined between the inner surface 25 and the outer surface 56 of the wall panel, without considering the contribution of plumb thickness 23 to the panel. wall. The main projection portion of the wall section can be a pultruded structural profile, which optionally includes thermally insulating foam in the pultrusion cavities. The foam may be thermally insulating material foamed in place in the pultrusion cavities. Alternatively, the foam can be fed as foam blocks in the pultrusion process in such a way that the pultruded fiberglass / resin composition forms around the foam blocks. The lower plate 16 and the upper plate 20 can be fixed to the main projection portion of the wall section with the support of the wedge-shaped supports 24 (Figures 2, 14, and 14A), or another support structure, optionally in combination with additional curable adhesive or polymeric resin. The selection of the adhesive depends on the selection of the material from which the upper plate is made, as well as the specific material and forms the pultrusion of the respective wall section, and the material from which the support is made 24. An exemplary adhesive is the Pro-Series QB-300 Multipurpose Adhesive, available through the OSI Sealant Company, Mentor, Ohio. Such adhesive can be used as desired to fix various elements of the building panel assembly

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10/203 each other.

The foam material in the wall panel cavities is of sufficient density, stiffness and polymer selection to provide the desired level of thermal insulation between the wall-facing surface and the wall-facing surface.

The bottom plate 16 can be a fiber-reinforced polymeric structural member, for example, reinforced with fiberglass, of such dimensions and structure so as to be sufficiently rigid, and with sufficient strength, to support not only the foundation wall but also the overlying building superstructure, from an underlying fabricated base defined, for example, by an aggregated stone bed 53 (Figure 6), from an underlying fabricated base comprising a concrete base 55 (Figure 3), or from another support base, manufactured suitable underlay. The specific structural requirements of the lower plate 16 can be elaborated based on the loads to be applied to the wall that is supported by the support base.

A fiber-reinforced product, pultruded, for example, from 1.9 mm (0.075 inches) to approximately 13 mm (0.5 inches) in thickness, has been considered satisfactory as the bottom plate for general family residential construction of general use and light commercial, and light industrial, typical.

The bottom plate can be fixed to the vertical wall section, and optional support brackets 24 using adhesive, using curable resin such as that used on the wall panel, using steel pegs

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21/103 that extend through a vertical leg of the base plate, etc., adjacent to the outer surface of the vertical wall section and through the adjacent portion of the vertical wall section, or by a combination of metal and adhesive piles and / or resin or by another fixation mechanism. In any case, the bottom plate, when attached to the vertical wall section, is sufficiently wide, thick, dense, and rigid, to provide effective compression and bending support, thereby supporting the foundation wall from the underlying soil. and / or rock and / or stone, or another natural base although typically through a manufactured floor.

The bottom plate typically extends laterally towards the building beyond the main surface of the inner layer by a distance corresponding to at least the maximum thickness of the building panel that includes plumb 123, thereby presenting a support surface adequately sized for the support base / underlying base whereby the overlying load can be supported by the underlying base without causing substantial vertical or lateral movement in the underlying natural support base of earth, stone, or rock. Alternatively, the bottom plate can extend outwardly from the building panel, moving away from the building, to provide the properly dimensioned support surface, cited, or it can extend not only inwardly but also in the direction out from the building panel.

The top plate can be made of layers wrapped in fiberglass, it can be a resin-fiber composite

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22/103 pultruded, may be conventional wood, or a manufactured wood product, or other conventional construction material, each such structure being sufficiently wide and thick to provide a supporting surface, establishing an interface with the underlying vertical wall section, and from which the building's overlying superstructure can be sustained. The upper plate can be conveniently made of conventional wooden building materials so that the overlying building structures can be conventionally fixed to the underlying foundation wall structure at the building site using conventional fasteners, conventionally fixed to the upper plate.

The combination of the inner and outer layers 34, 36 of the wall panel, and the reinforcement posts 123, are strong enough to withstand the inwardly oriented lateral forces, for example, bending forces that are imposed on a foundation wall by the ground, or on the walls above the ground by the wind loads, both imposed from outside the building.

A suitable illustrative base can be made from aggregate stone, shown as 53 in Figure 6, or concrete as shown in 55 in Figure 3. An exemplary aggregate stone has a size that passes through a 2.54 cm (1) mesh inch) and does not pass through a 1.9 cm (¾ inch) mesh.

With reference to Figures 1, 3 and 6, when the foundation wall 10 is in place as shown in Figure 1, on a suitable base (53, 55), a conventional ready mix concrete slab floor 38 is poured. The slab floor

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23/103 of concrete extends over, and thereby covers that portion of the bottom plate 16 that extends inwardly from any of the internal surfaces of the wall panels, including both, the main projection wall section and plumbs 23. That is, the concrete slab floor extends to, and leans against, the internal surfaces of the respective vertical wall sections, 18. Consequently, when the concrete slab floor is cured, lateral forces oriented inwardly, imposed by the soil outside the building, at the bottom of the wall, and taken in a direction aligned with the width of the lower plate 16, undergo resistance, are opposed, canceled, by the compressive resistance from side to side / side, structural of the concrete floor slab 38 in support of the foundation wall 10, when the edge of the slab leans against the inner surface of the foundation wall. Thus, the inwardly oriented lateral forces that are imposed on the foundation wall adjacent to the lower plate 16 are ultimately resisted, and are absorbed by the slab 38.

Inwardly oriented lateral forces that are imposed on the foundation wall in the upper plate or adjacent to the upper plate 20 can be transferred to the main floor 40 of the building (Figures 3, 6, and 6A), for example, by means of conventional mechanical fasteners and standard construction techniques that mechanically fix the main floor 40 and the foundation wall 10 to each other, or otherwise cause the main floor and the foundation to act together cooperatively.

Still with reference to the projection wall section

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24/103 main 22 (Figures 1, 3, and 5) and considering the structural environment of typical one-storey and two-storey residential construction, the inner pultruded layers 34 and outer 36 are, for example, between approximately 0.75 mm and approximately 12.7 mm (between approximately 0.03 and approximately 0.5 inches) in thickness. The thickness of the layers, internal 34 and external 36, are generally constant. The outer layer 36 can, for example, be reinforced with ribs to improve the ability of the wall to withstand the imposition of laterally oriented loads on the wall without further increasing the thickness of the layer.

In the modalities illustrated in Figures 1-5, the plumbs 23, where used, extend over the total height of the main wall section, and extend from the inner surface 57 of the inner fiberglass layer 34, inwardly by a desired distance in order to provide the desired level of structural strength to the wall panel 14. Thus, the uprights 123 function as reinforcing members in the wall panel 14.

In comparison, for example, with a thick wall section of 5.1 cm (2 inches), s 2.4 m (8 feet) high, without a reinforcement member, a corresponding wall that incorporates plumbs 123 in the centers of 40.6 cm (16 inches), and extends approximately 8.9 cm (3.5 inches) exhibits at least approximately 75% increased flexural strength. Such flexural strength is measured by applying a linear load that extends the length of the wall panel at the average height of the wall panel, and whose load is opposed by

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25/103 interlocking linearly opposite of corresponding extensions at the top and bottom of the wall panel.

With reference to Figures 1-5, in general, the inner and outer layers of the wall section are approximately 0.75 mm to approximately 12.7 mm (from approximately 0.03 inches to approximately 0.5 inches). thickness, optionally from approximately 1.3 mm to approximately 5.1 mm (from approximately 0.05 inches to approximately 0.2 inches) in thickness, optionally from approximately 2.2 mm to approximately 2.5 mm (from approximately 0.085 inches approximately 0.100 inches) thick. Thermal insulation foam can fill the entire space between the inner and outer layers, 34 and 36. The foam can also fill the plumbs, as desired.

The thickness T of the wall section (Figure 5) in the main projection wall section is defined without considering the dimensions of any plumbs 123, and is usually interrupted at the surface 25 of what is later defined here as space 131. The thickness T can be as small as approximately 5.1 cm (2 inches) between the inner and outer surfaces of the wall, up to as large as approximately 20.3 cm (8 inches) or more when measured between the outer surface of layer 34 and the outer surface of layer 36, and ignoring plumbs 123 for the purpose of defining thickness T. The typical T thickness of the wall is approximately 7.6 cm (3 inches) to approximately 15.2 cm (6 inches).

The top plate and the bottom plate can be

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26/103 conventional materials, for example, wood, with adequate waterproofing as appropriate for the intended use. To avoid problems of moisture contact with the wood, typically the bottom plate is a pultruded resin structure reinforced with fiberglass, of sufficient thickness and stiffness to provide the level of weight bearing capacity expected to be necessary to support the structure that must be sustained.

Structural building panels of the invention can be manufactured in any of the standard dimensional sizes, as well as in a variety of non-standard size combinations desired for a specific building project. Thus, for example, and without limitation, such panels are approximately 1.2 m (4 feet) high, which accommodate the use of the panels on 1.2 m (4 feet) frost walls. Height of approximately 2.7 m (9 feet) accommodates the use of panels on standard height basement walls and level walls above standard height.

The thickness T of the main projection portion of the panel typically ranges from approximately 7.6 cm (3 inches) of nominal thickness to approximately 20.3 cm (8 inches) of nominal thickness. Plumbs 123 can extend inwardly from such nominal dimensions. Additional flexural strength can be obtained through the use of plumbs that extend inwardly from the nominal thickness. Such plumbs extend inward by at least 7.6 cm (3 inches) to obtain the desired additional flexural strength, as well as to accommodate the properties of

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27/103 thermal insulation, desirable, with acceptable cost efficiencies, while facilitating the application of interior finishes to the wall. Such insulating properties can be obtained by adding conventional insulating material between the posts on the inner surface of the panel.

Typically, a T thickness greater than 20.3 cm (8 inches) is not required to satisfy the structural demands or thermal insulation demands in light-duty building implementations, cited here. However, in some cases, where extraordinary thermal or structural demands are being imposed on building panels, then a thickness greater than 20.3 cm (8 inches) is considered.

Panel lengths are limited only by transport limitations. For example, such panels can be as long as the length of the truck body that will transport the panels to the construction site. Thus, based on vehicle length restrictions on public highways, the length is generally limited to approximately 12.2 m (40 feet), but can be longer as desired where adequate transportation is available.

On the other hand, where adequate transport is available, the panels can be as long as desired for the intended purpose.

Structural building panels of the invention provide several advantages. For example, a structural building wall can be manufactured as a unitary structure at any height of the wall. Ignoring the

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28/103 transport limitations, panels can be assembled at the manufacturing site to any desired length, which can be a generic length, for example, 3.05 m (10 feet), 6.1 m (20 feet) , 9.15 m (30 feet), or 12.2 m (40 feet), or any length or length that is desired. The length of the wall 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 manufactured to a specific length at the manufacturing site panel. Thus, if a shorter length is required for a specific portion of the wall projection, the required length can be cut, for example, from a 6.1 m section. If a longer-length wall piece is required, a longer-length panel can be manufactured at the panel fabrication site, or multiple pieces can be joined to create the desired-length wall section. Such a union can be made at the construction site or the manufacturing site. The respective building panels can be cut to the exact length using, for example, a circular saw, a ring saw, or a reciprocating saw, using, for example, a masonry blade.

As the wall mounting is done mainly from fiberglass, the composition of resin, and foam, the density in pounds per cubic foot, and so the unit weight per foot in length is relatively small compared to a concrete wall. corresponding dimensions. For example, a building panel of

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10/29

6.1 m (20 feet) long, 2.4 m (8 feet) high, and a nominal thickness of 7.6 cm (3 inches), weighs approximately 329 kg, including the uprights 123 and the mounting brackets discussed elsewhere here.

Similarly, a 2.7 m (9 ft) high wall weighs from approximately 29.8 kg per linear meter to approximately 89.3 kg per linear meter, optionally approximately 40 kg per linear meter at approximately 81 kg per linear meter. Consequently, no crane is needed on site for wall mounting at ground level or close to ground level, or below ground level as for a foundation wall. More specifically, some of these wall panels can be moved only by hand. In some cases, a light duty crane would be useful.

Unfinished openings for windows 27 and / or doors 29, shown in Figure 1, can be cut in place as desired, using a masonry blade noted above. Accessories, and other connections between the wall elements and between the wall and other building elements, can be mounted by drilling and bolting conventional building construction elements / fasteners to the building panel, or using activated self-tapping fasteners. into the building panel, or through adhesive.

Figure 5 represents a top view of a portion of a foundation wall, including a 90 degree corner on the foundation wall. Figure 6 is a cross section, in elevation view, of a portion of the foundation wall shown in Figures 2-4.

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10/30

Figure 5 shows that a substantial part of the volume of the foundation wall is occupied by a series of cavities 196, filled with low density insulating foam 32. The inner, 34 and outer 36 layers of the fiberglass-reinforced resin form the layers generic, internal and external, of wall panels 14.

In general, the entire space between the inner surface of the panel and the outer surface 56 of the panel is occupied by layer 34, layer 36, reinforcement threads, intercostal 50, or foam, so that little, if any, of the space between layers 34 and 36 is not occupied by one of the panel materials mentioned above. Typically, substantially all of the internal space between layers 34 and 36 is occupied by the panel materials. By generally filling the space between layer 34 and layer 36 in this way, all panel elements are fixed in their positions relative to each other, and are fixed to each other so that the panel is dimensionally very stable under load designed, and a desired level of thermal insulation is provided. In addition, the panel is sufficiently resistant to the laterally oriented loads imposed on the panel, from outside the building, whether they are underground or above ground loads, for example, wind loads, so that such loads are efficiently transmitted from from the outer layer 36 to the other panel members, and respective portions of the layers 34 and 36, and intercostal wefts 50, and optionally foam 32, share the support of any load. The resulting panel is hard, rigid, and strong enough to support all loads,

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31/103 including severe weather loads, which the panel should typically be subjected to in normal use environments in an intended building structure, including normal seasonal environmental extremes in the given geographic location.

Plumbs 123 have multiple functions. As a first function, uprights 123 serve as mounting locations for mounting surface materials such as rock sheet, cladding, or other material on inner sheet 129, as shown in Figures 5 and 6, to form the finished inner surface the wall as an occupied housing space. Referring to Figure 17, the space 131 between the posts provides channels for installation, for example, of additional insulation 135, and / or utilities 137 such as electricity, plumbing, and / or air ducts. Such utilities can also be installed internally within the hollow space 133 within a plumb 123. Another main function of the plumb is that it optimizes not only the vertical compressive strength but also the resistance to the moment of load flexing located horizontally of the wall. Thus, the plumbs 123 and intercostal wefts 250 can be designed collectively to provide a substantial portion of the desired level of strength for the wall panel.

Figures 14, 14A and 14B illustrate the line representations of mounting brackets 24, 24A, and 24B. A support 24, 24A or 24B is mounted on the inner surface of the inner layer 34 at the top of the wall panel, using support panel 134, and the supports 24, 24A are optionally also connected to plumb 123 through a side panel of

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32/103 support 138. Referring to Figure 14, the upper panel 136 of the support 124 extends transversely from the top of the base panel 134 and is joined thereto. The first and second side panels 138 extend transversely from, and are joined to base panel 134 and upper panel 136, whereby upper panel 136 is supported from base panel 134 and side panels 138.

The base panel 134 of the support 24 is positioned against the inner layer 34 of the wall panel 14 and is mounted on the inner layer 34 and optionally is mounted on the plumb 123 on the side panel 138. Panels 134 and 138 can be mounted on the inner layer and plumb 123, for example, by means of adhesive. The upper panel 136 establishes an interface with the upper plate 20 and supports it and is typically screwed onto the upper plate as shown in Figure 6. The support 24 serves to transfer a portion of the load, on the upper plate 20, to the main portion of the panel wall, thereby making the top plate an integral part of the foundation wall. Other portions of the top plate load are transferred to the wall panel by surface-to-surface contact between the top plate and the uprights 123. Still other portions of the top plate load are transferred to the wall panel by direct surface-to-surface contact. between the top plate and the top of the main projection portion of the wall panel, optionally through a support 48 or 188, as shown in Figures 6, 6A, 6B, and 15.

One of the side panels 138 is used to fix the support 24 to the plumb 123, while the base panel 134

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33/103 is used to fix the support to the inner layer 34. Consequently, the second side panel has no necessary fixing function, and thus can be omitted in some modalities. The support 24A of Figure 14A illustrates such an embodiment where support 24A is the same support 24 of Figure 14, with the exception of providing only a single side panel 138. In the embodiment of Figure 14A, any of the panels 134 and 138 can be used , facing the inner layer 34 or plumb 123.

In addition to transferring compressive load forces from the overlying building load, the supports 24 and 24A transfer the lateral loads from the landfill, which acts on the wall panel, and transfer such lateral load through, for example, from pin 139 to the top plate 20 and finally to the overlying floor 40, the side loads are generally dissipated on the floor 40. Since the supports 24, 24A depend on mounting on the posts 123, the spacing of the supports 24, 24A is limited to not more often than the spacing of the plumbs, so that some lateral arching of the wall panel can be experienced, from plumb to plumb between the supports.

In the embodiment of Figure 14B, the support 24B resembles an angle bracket length, but is preferably manufactured from FRP materials, for example, it is pultruded in such an angular configuration. The support 24B is conveniently dimensioned in the length of approximately 30.5 cm, so that the length of the angle bracket readily extends between the uprights 123 on opposite sides of a cavity 131. Each flange 134, 136 extends approximately 5.1 cm from the union of flanges 134,

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10/34

136, illustrated how 145. O 24B support is assembled with The long dimension of Support if extending over of length of panel between at edges, 216 and 218, with one

of flanges 134, 136 in relation to surface to surface with cover 342 (Figure 6C) or upper plate 20, and with the other of flanges 134 and 136 located against the inner layer 34 or another corresponding inner surface. As the length of the support 24B extends along the length of the wall panel, the support can be mounted by means of adhesive on the upper plate substantially along the total width of the cavity 131, from plumb to plumb. Alternatively, or in addition, several fasteners can be employed along the length of the support, attaching the support to the cover 342 or top plate 20 at intervals generally narrowly spaced as desired through the openings 141 to prevent lateral arching of the wall panel between the plumbs 123.

Brackets 24, 24A, 24B can be made of materials other than FRP materials, but FRP materials are preferred to maintain the common material identity as reasonably as possible throughout the wall structure.

Figure 6 illustrates, in side elevation view, the interface of the upper plate fixing support 24 with the upper plate 20. In the illustrated embodiment, the upper plate is a conventional wooden plank, and is attached to the support 24 by means of a peg 139 through the top panel 136. Figure 6 also illustrates a second fixing bracket 24 used to support the interface between the wall panel and the bottom plate 16. Brackets 24, 24A and 24B can be used on the bottom plate as well as on

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35/103 upper plate.

Figure 5 illustrates the joining of two wall panels 14A and 14B using a corner support 160, which has connectors, male and female, at right angles to each other, which can be used to join two wall panels in one right angle corner. Figure 5 also shows the in-line joining of wall panels 14B and 14C to each other using edges, male, 216, and female, 218, which are formed in the wall panels when the panel structure is formed, and in which the male edge is received at the female edge and joined to it as part of the edge to edge joining process of adjacent panels of the wall panels. Typically, curable adhesive or resin is used in such an edge-to-edge joint.

Figure 5A illustrates an exemplary glass structure for a pultruded panel of the invention, where uprights 123 are integral elements of the panel. Figure 5A shows three main structural fiberglass layers in the outer layer 236, two main structural fiberglass layers in the inner layer 234, a third main structural fiberglass layer in the posts 123, and fiberglass wicks and continuous filament mats or cut filament mats in the intercostal wefts 250. The voids between the illustrated fiberglass elements and the matrix elements represent the space that is occupied by the resin composition in the pultruded structure.

Figure 5A is actually an exploded view in such a way that the space indicated for the resin is especially exaggerated.

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10/36

Figure 6 illustrates, in end view, the addition of a fiberglass / resin support bracket 48 (Figure 13) against the outer surface 56 of the wall. Figures 4 and 6 also illustrate, from a side elevation view of the external surface of the wall, the extension of the support bracket 48 as a layer of bricks, along the total extension of the main projection wall section. The support 48 transfers the weight of the overlying bricks 75 to the underlying wall 10.

Still referring to Figure 6, the support bracket 48 extends outwardly from the outer surface 56 of the wall panel by a sufficient distance, such as approximately 10.1 cm to approximately 12.7 cm, to support brick or conventional stone, or any other covering on the outside of the building. As indicated in Figure 6, after construction work is completed, earth or other landfill 174 typically fills the cavity dug around the foundation wall, to a level at or above the brick support panel 176, thereby hiding the support 48.

Support bracket 48 can be installed facing inwardly on top of a garage wall, for example, thereby providing the vertical edge support to a subsequently dumped concrete garage floor. Similarly, support 48 can be installed facing outwardly on top of, for example, a garage or other wall, thereby providing vertical edge support for subsequently installed brick or stone, or to support, for example, a roof covering. concrete slab garage. O

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37/103 first and the second complementary support 48 can be mounted, on top of each other, with the 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 support for both, a foundation wall of continuous edge of the garage floor and brick or stone or other outdoor platband, both of which are adjacent to the foundation wall.

A trace representation of support bracket 48 is illustrated in Figure 13. In the vertical use orientation shown in Figures 3, 6 and 13, a base panel 178 of support 48 is oriented vertically along the outer surface 56 of the building panel 14, and optionally can be attached to panel 14. Brick support panel 176 extends outwardly from the base panel, above the bottom edge of the base panel. A shoring panel 180 extends upwards from the lower edge of the base panel to the outer edge of the brick support panel, transferring the structural support oriented upwards from the base panel to the outer edge of the brick support panel. An upper panel 182 extends horizontally from the upper edge of the base panel and ends in a downwardly oriented retaining panel. The top panel 182 and the retainer panel 184 collectively mount / hang the support bracket 48 from the top surface of the wall panel 14.

Figure 15 illustrates a second modality of the support bracket, that is, a two-sided support bracket that is

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38/103 designated as 188. Support 188 is designed and configured to support both: (i) an edge of a garage floor that usually leans against the surface facing inwardly of the foundation wall and (ii) a plateau of brick or stone, or a concrete slab garage cover, which usually faces the surface facing outwardly from an upper portion of the foundation wall, as well as to interface with a vertical wall, for example, above level covering the foundation wall. The edge of the garage floor covers a first support panel of the support bracket and thus loads the support bracket on the side towards the foundation wall. The brick or stone plateau, or garage cover, covers a second support panel of the support bracket and thus carries the support bracket on the side facing away from the foundation wall. The loads imposed on the support panels are passed from the support support through the foundation wall to the base, and from there to the underlying soil or another natural base that supports the respective wall.

As with the support bracket 48, the two-sided support bracket 188 is installed on top of the wall panel in such a way that the upper panel 182 rests on the upper surface of the wall panel. Base panel 178A extends downwardly from upper panel 182. Support panel 176A extends outwardly from base panel 178A, and is supported by shoring panel 180A. A second base panel 178B extends downwardly from the top panel 182, typically, but not

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39/103 necessarily, for a similar distance as that of the base panel 178A in order to end at a lower edge that generally has the same elevation installed as the base panel 178A. The support panel 176B extends outwardly from the base panel 178B, and is supported by the shoring panel 180B.

A single support bracket 188 can thus be used instead of the first and second support bracket 48 mentioned above where a leveled concrete garage floor leans against the top of the foundation wall and a brick or stone plateau, or roof garage, is mounted on the other side of the foundation wall.

Similar to the operation of support 48, support panels 176A, 176B transfer the weight of the overlying loads of the brick or stone plateau, or garage cover, and the edge of the garage floor, to the wall, from that place through the base, and for the underlying natural base, for example, of the soil or rock that supports the building.

As shown in Figures 6A, 6B, the supports 48, and the corresponding supports 188, can be used to support the lower parts of the floor joists or other floor support members below the top of the wall such that the top of the floor 40 is at an elevation not exceeding a height that is defined above the foundation wall by 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 arranged in the direction to

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40/103 inside the outer surface of the foundation wall and inwards towards the surface facing inwards 25 of the foundation wall. The subfloor and finished floor, which cover the floor support members, can extend beyond the floor support members as desired such as on panel 182 and support 48. Such a decrease in height, for example, from a ground floor it can facilitate construction for people with disabilities to enter the building.

Similarly, supports 48 can be configured to support the lower parts of the floor joists at any desired elevation below the top of the wall such that the top of the floor is at a corresponding elevation, for example, in height intervals of 1 mm in relation to the top of the foundation wall, up to a height that is approximately identical to the elevation shown in Figure 6. Such a configuration of supports 48, 188 can thus be used to support floor beams corresponding to the building floors that are level above as well as the building floors that are below the level. For example, where two floors of a building are below level, supports 48 can be used to support floor joists, or floor frames, on floors below level, as well as one or more floors above level.

Although the supports, 48 and 188, have been described here as being used with building panels of the invention, the supports, 48 and 188, when properly dimensioned and configured, can be used with conventional walls, for example, concrete such as walls frost and foundation walls since the top panel 182

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41/103 is dimensioned for accommodation in such a conventional wall.

Returning again to Figure 6, the lower plate 16, as illustrated, can be more properly thin, for example, from approximately 4.6 mm to approximately 12.7 mm thick, hard and rigid resinous pultrusion that has sufficient hardness and rigidity to diffuse the vertical load for which the panel is designed, substantially over the entire downward facing surface area of the bottom plate, thus transferring the vertical load to, for example, the underlying aggregate stone, or other fabricated base.

In some embodiments, a conventional concrete base 55 (Figure 3), for example, is interposed between the underlying natural soil, or the clean aggregate stone base, and the bottom plate 16. In such a case, any of a wide variety of conventionally available, malleable, crushable material, curable liquid, paste, or the like, deformable seal or other bonding material 51 changeable, or sealing material or other bonding material of a definite but crushable form, such as sheet metal , is seated on the base before the wall panel is placed on the base. Connecting material 51 is illustrated as a thick dark line somewhat irregular between the concrete base 55 and the bottom plate 16 in Figure 3. The wall panel is installed over the intermediate sealing material or other deformable material before a material deformable harden, so the small interstices, spaces, between the base and the wall panel are filled by

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42/103 deformable material.

When the deformable material is cured, the deformable material becomes rigid, whereby the bonding material transfers corresponding portions of the overlying load through potentially existing spaces, which have been filled with the bonding material, thereby providing a sharing interface. continuous load between the wall panel and the base along the full length of the wall panel. Such a bonding material can be any material sufficiently deformable to assume the contours not only of the lower surface of the plate 16 but also of the upper surface of the base, and which is curable to create the structural bonding configuration mentioned above.

With reference again to Figures 3 and 6, the concrete slab floor 38 is shown overlying that portion of the lower plate 16 that extends inwardly from the inner surface 57 of the wall panel 14, and in the direction inward from channel plumbs 123. The slab floor 38 adjoins the inner surfaces of wall panel 14 and channel plumbs 123, thereby stabilizing the lower end of the wall panel against inwardly directed forces that reach the bottom end of the wall panel. In some embodiments, the bottom plate 16 extends only to the end panels 130 of the uprights 123.

As desired, the supports 24, 24A, 24B can be additionally fixed to the uprights 123 and / or main projection wall section 22 by using fasteners

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43/103 such as screws or bolts through openings 141 in the base panels 134 or side panels 138 of the supports.

Mechanical connection structures, such as dowels, screws, or brackets, are spaced along the length of the wall, attached to, and extending from the posts 123, or attached and extending from the main projection portion of the wall, below the top of the concrete slab 38.

Another exemplary connection structure consists of one or more extensions of steel reinforcement bar (rebar) or a fiber reinforced polymeric reinforcement bar (FRP), which extends along the length of the wall panel, and through one or more of the plumbs. For example, a short bar can be used on each plumb, extending outward from each plumb leg. A single bar can extend through one or more plumbs, or all plumbs on a given wall panel, so the length of the reinforcement bar generally matches the length of the panel. The flowing concrete flows around such connection structures before the concrete hardens in such a way that the hardened concrete grips such connection structure, and is thus trapped in the connection structure, thereby preventing the concrete slab from loosening from the wall. . Figures 6 and 6A illustrate such a mechanical structure, for example, a reinforcement bar, in an end view at 143, extending from a plumb line and along the length of the panel.

As a combined structure, support 24B can be manufactured as a U-shaped channel support, having

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44/103 the base panel 134, upper panel 136, and a lower panel 147 opposite the upper panel 136. Such support is installed adjacent to the lower plate 16 with the base panel 134 horizontally oriented against the lower plate 16, with the panel upper 136 against the inner layer 134, and with the lower panel 147, parallel and spaced from the upper panel 136, whereby the lower panel 147 may have the function of being gripped by the floor slab 38.

Although described using different nomenclature, that is, the wall surface and the inner surface, the inner surface 57 and the wall surface 25 represent the same face of the wall panel 14 when considered away from the plumbs 123. Unlike surface 25, the inner surface 57 also includes the respective surface of the wall panel on the uprights 123.

Inwardly oriented forces reaching the upper end of the wall panel are opposed by the fixings between the overlying main floor 40 and the upper plate 20. The inwardly oriented forces that are imposed on the wall panel 14 between the top of the wall panel and the bottom of the wall panel are transferred to the top and bottom of the wall panel through the hardness and rigidity of the wall panel as defined collectively by the interactions of the structure defined by layers 34 and 36, intercostal wefts 50 , foam 32, and plumbs 123, if used. Another reinforcement structure can be included added to the wall if and as desired to obtain the desired level of lateral strength and stiffness in the wall structure. Such loads are transferred to the slab floor 38

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45/103 at the bottom of the wall by meeting the concrete slab against the wall; and are transferred to the overlying floor at the top of the wall through the supports 24, 24A, 24B as appropriate, and pins 139 where used, or through the cover 342, upper plate 20, and fasteners 362.

In residential construction, a typical vertically oriented maximum load experienced, for example, by an underlying foundation wall is approximately 4,170 kg per linear meter to approximately 7,450 kg per linear meter. The vertical load can be applied to the full width of the top of the wall at any location along the length of the wall, including plumbs 123.

Referring to Figure 5, a typical wall panel of the invention, for use in individual family residential underground applications such as foundation walls, has a nominal thickness T of approximately 7.6 cm. Plumbs 123, if used, for example, as in Figures 5, 6 and / or 17, project away from the outer layer by a distance of approximately 8.9 cm from the inner surface 25 of the wall panel. The inner layer 34, the outer layer 36, and the intercostal reinforcing webs 50 are all approximately 2.3 mm thick. Plumbs 123 have walls approximately 2.3 mm thick. The foam 32 has a density of approximately 32 kg / m ³ to approximately 80 kg / m ³ . Such a typical wall panel has a vertical crush resistance capacity of approximately 22,313 kg per linear meter. The distance / depth through which plumbs 123 can extend if

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46/103 moving away from the outer wall panel can vary from approximately 2.5 cm to approximately 25.4 cm. The ratio of plumb depth to plumb width generally ranges from approximately 1/1 to approximately 3/1. Depth less than 2.5 cm provides little benefit in terms of strength or space for installing utilities. At more than 15.2 cm in depth, absolutely larger widths of the plumbs suggest less value to the plumb concept, compared to a thicker main projection wall section.

Both, the resistance to vertical crushing and the resistance to the moment of flexing of localized load can be projected to relatively greater or lesser magnitudes by specifying, for example, and without limitation, the included foam density; thickness of layers 34 and / or 36, and / or intercostal wefts 50; wall thickness, spacing, and / or depth T1 (Figures 5 and 17) of plumbs 123, or thickness T of the panel, or thickness T in combination with the depth T1 of the plumbs.

The panels that are to be used in level-level applications are designed to meet the load requirements experienced in level-level applications while the panels that are to be used in level-level applications are designed to meet the load requirements experienced in level-up applications. Such a design process includes considering the history of weathering and / or soil movement from the site of use, as well as other environmental factors. In this way, the building panels of the invention include a wide range of structures and

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47/103 panel properties, in order to provide planned solutions that can be designed to accommodate the stress environments that must be imposed on specific building panels that must be used for specific uses. Of course, you can also make building panels out of generic models that are designed to tolerate a wide range of expected loads. For example, a first design specification can be made to meet most uses at the lower level while a second design specification can be made to satisfy most uses at the higher level. Such standardization can reduce costs per unit of processing, while accepting material costs that are excessive for many of the intended uses.

Given the conventional wisdom that concrete is generally not deflected before failing catastrophically, and that concrete is conventionally used in foundation walls level below, applicants believe that there is no universally recognized standard with respect to the allowable amount of lateral deflection of such a wall under load.

Since the walls of the invention are made from FRP compositions, which can tolerate a certain deflection without catastrophic failure, those skilled in the art can predict that the walls of the invention can be deflected under nominal load.

Figure 6C is another embodiment in an enlarged view of an upper portion of another foundation wall structure. In the embodiment illustrated in Figure 6C, the main projection portion 22 of the wall panel is filled with

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48/103 foam as indicated in 32 and as shown generally, for example, in Figures 5 and 19. The inner layer 34 is on the inner surface of the foam. The outer layer 36 is on the outer surface of the foam. The inner layer 34 also extends around the various vertical uprights 123 that are spaced along the length of the wall panel, and which extend, from the inner surface of the foam, in the opposite direction to the outer layer until the end 130. In general, the wall panel 14 illustrated in Figure 6C can represent any and all wall panels of the invention where the uprights 23, 123 extend from the main projection portion of the wall panel, away from the outer layer 36.

The structural cover 342 covers the top of the wall panel, including the main projection wall portion, the plumbs, and the utility cavities 131 between the plumbs, and extends downwards over the outer surface of the wall panel and on the internal faces of the plumbs. Thus, cover 342 has a horizontal plate 344 that covers and contacts the top of the wall panel. The horizontal plate 344 generally extends the full length of the wall panel, and extends from the outer surface of the outer layer 36 to the exposed outer surfaces of the end panels 130 of the uprights 123. A flange 346 extends downwards , from the inner edge of the horizontal plate 344, to a first distal end 348. An outer flange 350 extends downwardly, from the outer edge of the horizontal plate 344 to a second distal end 352.

The cover 342 is affixed to the wall panel 14. A

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49/103 wide variety of methods can be used for such display. For example, the cover can be adhered to the wall panel on the respective interface surfaces using conventionally available construction adhesives. Alternatively, screws or other mechanical fasteners can be applied spaced along the length of the wall panel, for example, through the inner flange 346 and into the posts 123, and through the outer flange 350 and into the wall section of main projection, thereby to fix the cover 342 on the underlying wall panel.

In the illustrated embodiment, the upper plate 20 covers the cover 342. The upper plate 20 diffuses the load from the overlying floor 40 and from another structure the entire upper plate 344 of the cover 342.

Frame beam 354 covers and rests on the upper plate 20 and extends along the length of the upper plate 20, cover 342, and thus along the extension of the respective wall. Several floor beams or floor frames 356 are spaced along the length of the upper sheet 20, and thus along the length of the frame beam 354 and extend transversely from the frame beam 354 into the building, thereby provide support for the overlying floor 40.

The conventional overlying wall plate 358 covers the floor 40. The wall plate 358 and its overlying structure, shown only in the nominal part, represent the overlying walls that enclose the respective floor / floor of the building together with any other building structure, and the associated loads, which

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50/103 are supported on the foundation wall through the floor 40, beams or stringers 356, frame beam 354, top plate 20, and finally the cover 342.

The rim beam 354 is affixed to the upper plate 20 by means of a plurality of nails or screws 360 that are spaced along the length of the rim plate and beam. The wall plate 358 is screwed or nailed to the floor joists and frame joists, for example, by means of a plurality of screws or nails 364.

Several fixing screws 362 extend upwards in the utility installation cavities / spaces 131 between the uprights 123, through the cover 342, through the top plate 20, and into the beams or frames 356. The threads of the screws penetrate in the material of the beams or frames 356, and thus provide direct fixing connections, spaced along the length of the building wall, between the foundation wall 12 and the overlying floor so that the risk of movement of the building structure overlying outward foundation, for example, due to extreme environmental tensions, is substantially reduced. The screws 362 are easily applied / inserted after the foundation wall is erected due to the availability of the cavities 131 between the plumbs.

Where space is available within the overlying structure, such as above the bottom stringer of a floor frame, upwards vertically extended bolts can be used instead of upwardly extended fixing screws and optional nuts and washers can be used on the pegs, in this way to secure the frame or other structure

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51/103 overlying the underlying wall. Other upwardly oriented mechanical fasteners such as nails can be used instead of the aforementioned and illustrated screws, provided that the respective fasteners provide the desired level of attachment between the overlying structure and the underlying wall. In the illustrated embodiments, the cavities 131 provide access through the bottom of the cover for applying such fasteners to the beams or frames 356. Other access cavities may be provided as desired, in addition or in place of the cavities 131, for the purpose of providing actuation access for activating fasteners through the roof and into the overlying structure.

The specifications for the cover 342, different from the profile in cross section, are generally identical to the bottom plate 16. Thus, a cover that is a pultruded structure, for example, from 2.3 mm to approximately 12.7 mm in thickness generally it is suitable for common use in single-family, light commercial, and typical light industrial construction. In any case, the cover 342 is sufficiently thick, dense and rigid to provide effective compression and flexing support, thereby to spread the weight or other loads of the overlying building structure over the top end of the wall panel and over it including on the main projection wall section and on the plumbs 123.

The cover 342 can, alternatively, be made of overlapping layers of fiberglass, impregnated with a

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52/103 curing resin, and subsequently cured as discussed here with respect to the bottom plate 16.

Still referring to Figure 6C, in some embodiments, the upper plate 20 can be omitted, so that the cover screws 362 extend from the cover 342 directly into the beams or frames 356; and nails or screws 360 extend from the frame beam 354 directly into the cover 342, optionally with initial holes previously being made in the frame and cover beam. In such embodiments, the cover 342 performs the function mentioned above for the cover, as well as the functions typically performed by the upper plate 20.

Alternatively, cover 342 can be omitted, the top plate 20 can be attached directly to the underlying panel, and the screws 362 extend through the top plate 20 and into the overlying floor structure. One way of attaching the upper plate to the wall panel is to position a support 24B in the corner defined by the panel 14 and upper plate 20 such that one flange of the support is against the inner surface of the wall panel and the other flange is against the top plate. Screws through the respective flanges thus secure the upper plate to the wall panel.

Figure 6D illustrates a wall similar to that of Figure 6, with soil force vectors, lateral applied at 0.3 mm intervals along the height of the wall. Figure 6E illustrates the same lateral soil forces in the form of a table for three different wall heights for each of the three different types of soil.

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53/103

In the development of the wall and wall panels of the invention, the inventors present here determined that acceptable lateral deflections in the wall panels of the invention are generally related to the total height of the wall for a given floor of the building, according to the formula

H / 240 = maximum allowable deflection, where H and the allowable deflection are both expressed in the same unit of measurement.

For example, a foundation wall that has a height of 2.7 m (9 feet) has a maximum acceptable deflection calculated as follows:

274.3 m / 240 (108 inches / 240) = 1.14 cm (0.45 inches) maximum allowable deflection

EXAMPLE

Walls made according to this invention can easily satisfy the deflection pattern above, given the following specification:

Panel height 2.7 m Total thickness 17.5 cm Thickness, section wall of projection 8.3 cm main, including bed from 34 and 36 Plumb depth 9.2 cm Layer thickness 34, 36 2.3 mm Wall thickness sides of plumb and 2.3 mm

end panels

Glass specification as described below with reference to Figure 5A.

Applicants surprisingly found / observed that when vertical walls and panels

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54/103 of walls made according to the above specification are subjected to upper / compressive loads that are equally distributed from the outer layer 36 of the main projection wall section to the end panels 130 of the uprights, such walls and panels of wall are deflected out of the building, towards the outer layer 36, 326, that is, towards the ground embankment. Thus, the load of the horizontal / lateral natural soil applied by the grounded soil, is at least partially neutralized by the opposite forces resulting from the building's compressive load. When the wall deflects against and towards the grounded ground, that portion of the building's compressive / gravity load that is expressed outwardly is thus dissipated in the adjacent grounded ground. Thus, the deflection of the wall in the outward direction, resulting from the overlying building load, balances some or all of the horizontal soil load, oriented inwardly on the wall. As a result, these opposite lateral forces on the wall tend to balance each other, thereby leaving a resulting relatively lower horizontal load on the foundation wall. Although the inwardly oriented soil load can be calculated as in Figure 6E the magnitude of the outwardly oriented building load also depends on the structure of the overlying building on the structure of the wall and wall panels.

While preferring not to stick to the theory, the inventors here consider that such outward deflection may be a result of the C / L load axis (Figure 5)

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55/103 along the horizontally measured extent of the vertical wall panel, being spaced inwardly from the inner layer 34, from the inner surface 25. Given a general balance of resistances per linear foot in the inner layer 34 , the outer layer 36, plumb legs 128, and plumb end panels 130, the load-carrying capacity of the posts 123 may be less than the load-carrying capacity of the main projection wall section, so the posts 123 they can compress to a greater degree than the main projection wall section, whose upper plumb compression would translate into an outward deflection of the wall towards the ground embankment.

Thus, it would appear that such an outward wall deflection could be expected at any time when the center line of the load balance is over cavity 131 and the load capacities of the plumb layers approach the load capacities of inner and outer layers 34, 36.

Returning to Figure 1, as suggested above, conventional steel beams can be used in combination with the wall panels 14 of the invention. As shown in Figure 1, such I-beams are supported from the underlying soil in conventional spacing by the pillars 28 that transmit the loads from the I-beams to the underlying soil, through a load diffusion block 30. In structures conventional, the load is transmitted through the conventional steel pillar, to an underlying concrete base block that is dumped into the underlying soil.

In the invention, in the interest of avoiding the need for

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56/103 a mix truck ready for small loads, so instead of a concrete base, multiple layers of reinforced polymer composite are used in the manufacture of a support block 30. A typical support block 30 is illustrated in Figure 7, underlying a support pillar and supporting a structural floor support beam 26.

A cross section of a representative block 30, on an underlying support base SB is illustrated in Figure 8A. As illustrated in Figure 8A, block 30 has an upward facing top 30T and a downward facing bottom 30B. The surface area of the bottom of the block is selected to be large enough to spread the overlying load over sufficient natural soil and / or the underlying rock support base so that the underlying support base can support the overlying load for a period of generally indefinite time without harmful deformation or flow, whether vertical flow or transverse flow, or other movement of the underlying support base. The block is constructed of a plurality of generally extended layers of composite fiberglass-reinforced polymer 31 layers. The layers, in general, are positioned in such a way that at least a substantial portion of a relatively overlying layer covers a substantial portion of a relatively underlying layer. Typically, the layers are stacked on top of each other, optionally connected together at the edges 33, as by folding from one layer to the next top or bottom contiguous layer, such that the respective stacking of the layers, layer upon layer, results in portions usually arranged

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57/103 horizontally, facing the respective layers supporting each other, and acting collectively, in this way to provide blocks that have sufficient flexural strength to support downwardly oriented loads when the blocks are in use.

Such a layered arrangement can be created by folding and stacking a layer of fiberglass moistened with resin in a moist mold, closing the mold and evacuating air, thereby consolidating the block, and then curing the resin, resulting in in the fiber-reinforced polymer block, hardened. Alternatively, the fiberglass layered arrangement can be placed in a dry mold in the dry condition, and the resin can be infused into the mold while the mold is being evacuated.

Block 30 is illustrated in Figure 7 as having a generally square or round projected area, and as being used for localized support such as in the support of a pillar 28. Block 30 can have a projected area expanded from any desired projected configuration in such a way. so that a single block is under and supports multiple pillars in an area. In addition, block 30 may have an elongated configuration whereby block 30 can be used as an elongated base under, and supporting, any number of foundation panels 14 when the panels are used on a fabricated foundation wall.

Thus, a typical support block can have a projected area of approximately 0.09 m ² to approximately 0.9 m ² when designed to support a localized load such as a single pillar. A block that is designed to support, for example, an elongated load such as a

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58/103 wall having a length of, for example, 3.05 m (10 feet), 6.1 m (20 feet), 12.2 m (40 feet), or more has an elongated dimension corresponding in magnitude to the length the wall.

The thickness of the block is designed to withstand the magnitude of the predicted overhead load. Thus, as with building panels, for each building application, the block represents a planned solution based on the expected load and load distribution. The magnitude of the load when sustained by block 30 generally corresponds to the load distribution conventionally considered for typical single-family residential construction. Thus, the load distribution cited here for the foundation walls can be applied in such a way that an elongated block can support at least 7,500 kg / linear meter and a round or square block can support loads of at least approximately 9,760 to approximately 24,400 kg / m ² , more typically approximately 14,640 to approximately 24,400 kg / m ² . Higher loads can be supported by proper construction of such blocks.

The thickness of a block, between the top 30T and the base 30B depends partly on the magnitude of the load and the load distribution, and partly on the specific resin as well as on the specific structure of the reinforcement fibers and fiber layers, as well as on the nature of the block construction. For lightweight construction, where the block carries a relatively lighter load, the thickness of the block can be as small as 2.5 cm. Where the block supports heavier loads, the block is thicker, and generally has the same

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59/103 order of magnitude of thickness that would have been used if the material were concrete reinforced with steel. Thus, the thickness of the block typically ranges from approximately 7.6 cm (3 inches) thick to approximately 40.6 cm (16 inches) thick, optionally approximately 15.2 cm thick to approximately 40.6 cm (16 inches) thick, optionally approximately 20.3 cm (8 inches) thick to approximately 40.6 cm (16 inches) thick, with all thicknesses between 2.5 cm and 40.6 cm (16 inches) ) being considered. Thicknesses less than 7.6 cm (3 inches) and greater than 40.6 cm (16 inches) are considered where the expected vertical load and load distribution, together with the material properties, indicate such thicknesses.

In general, the thickness dimension is less than the length or width dimension. As illustrated, for example, in Figure 1, typically the magnitude of the thickness dimensions is not more than half the magnitude of the smallest length dimension or wide dimension.

In any case, the structure shown in Figure 8A is not limiting in relation to the structure of the layer. For example, the fiberglass layers can be configured as an elongated roll, where relatively outer layers are wrapped around one or more relatively inner or core layers.

Alternatively, as shown in Figure 8B, block 30 may be a polymeric structure reinforced with pultruded glass fiber such as a pultruded sheet

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60/103 solid or a rectangular tube positioned in such a way that one or more cavities 37 generally extend horizontally through the structure. Such a rectangular tube has an upper or inner frame generally horizontal 30TW, a lower or outer frame generally horizontal 30BW, and one or more connecting frames generally vertical 35 that support the upper frame from the lower frame. In the embodiment illustrated in Figure 8B, the cavities 37 are hollow. In other embodiments, a honeycomb or other weft structure extends the length of the cavity 37, thereby providing a connection structure between the upper weft 30TW and the lower weft 30BW, which can provide structural support sustained to the upper weft from the weft and thus assume part of the support function of the frame or connection frames 35.

The pillar 28 is represented generically in Figure 1. Although the pillar 28 can be made of steel and the block 30 can be made of concrete where the wall panels of the invention are used, the invention considers that the pillar 29 is a composite structure of reinforced polymer -hollow glass fiber. Resin that cures as in the block and building panels can be used to assemble and connect pillar 28 to the block, with conventional paving as desired.

Such a resin-fiber composite pillar 28 has a generally surrounding structural side wall. The side wall of the column is made of fiberglass-reinforced polymer composite or other fiber-reinforced resin structure. The thickness and stiffness of the column sidewall are designed as known in the art

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61/103 to carry a specified load, thereby to support the weight of an overlying portion typically of an upper level structure, although the lower level structures may also be supported. The surrounding pillar side walls define an inner chamber arranged inwardly towards the surrounding side wall. The inner chamber is typically empty, but can contain structural or non-structural material as desired.

Where a 28 fiberglass post is used, a 58 fiberglass reinforced polymer composite cover is typically mounted on top of the post. The cover 58 has an upper wall 60, and one or more structural tabs hanging downwards 62. The side wall 60 of the cover is sufficiently thick and rigid to receive the load from the overlying beam and transmit the load in a generally uniform manner around the perimeter of the wall or vertical outer walls of the column, including where the outer walls can be arranged laterally outwardly from the edges of the beam. The structural flap or flaps are configured in such a way that when the roof is mounted on the pillar, with the top wall of the roof resting on the top of the pillar, the internal surface of the structural flap or flaps is generally in surface to surface contact with, or in close proximity to the outer surface of the column, such that the flap structure receives and absorbs the lateral forces typically encountered and transfers such lateral forces to the side wall of the column, thereby preventing the top of the roof from moving laterally in relation to the top of the pillar.

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62/103

The roof distributes the side loads to the side walls of the column with limited flexing of the top wall of the roof, in order to use the load-bearing capacity of the side walls of the column, from or near the top edge of the column, along from the total height of the column to the underlying block 30. The cover flaps thereby capture lateral forces and transfer lateral forces to the column.

An alternative to cover 58 is to use a conventional adjustable screw 59 on top of pillar 28. Such screw 59 can be used in place of cover 58, or in combination with cover 58, for example, between cover 58 and the beam overlying 26. Where both cover 58 and screw 59 are used, a suitable screw / cover interface is configured on the screw and / or cover to ensure proper cooperation of the cover and screw with each other.

Figure 9 illustrates a square 30 fiberglass-reinforced polymer composite block of the invention, a square 28 fiberglass-reinforced polymer composite pillar, and a square fiberglass-reinforced polymer composite cover 58 of the invention. Figure 10 illustrates a block / pillar / cover combination similar to that of Figure 9, but where the block is tapered from the top of a block base upwards to where the block meets the pillar. Figure 11 illustrates a block / pillar / cover combination similar to that of Figure 9, but where the column, block, and cover are circular. Figure 12 illustrates a block / pillar / cover combination similar to that in Figure 11, but where the block is tapered to

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63/103 from the top of a column base upwards to where the block meets the column.

Although the block / pillar / cover combinations shown in Figures 9-12 can be used inside the building as in a basement column arrangement, as suggested in Figure 1, the main objective of the invention, to avoid the need to bring a ready mix concrete truck for the construction site, is perfected using block / pillar / cover combinations such as those illustrated in Figures 9-12 in applications outside the building foundation, such as to support a deck, a balcony, patio, lamppost, or other attachment. In such an application, the block and the pillar are mounted on the ground below the frost line. The pillar is then typically cut, but not necessarily, level down. Conventional structure such as a 4x4 treated wooden pillar is then mounted on top of the roof 58, and the roof is subsequently mounted, for example, adhesive-mounted on the top of the pillar, with the roof flap extending below the top of the pillar. With, for example, the 4x4 pillar thus extending upwards from the cover, with the cover, for example, permanently mounted by adhesive on the pillar, the hole is filled to the level in such a way that only the conventionally used wood remains visible. Thus, typical external accessories for the building can be completed, again without any need to bring ready-mixed concrete, or concrete block, to the construction site, and only with conventional materials being visible above the finished surface.

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64/103

This can provide a significant advantage in terms of time and cost when only a small amount of concrete would otherwise have been necessary, since the transport cost by truck is fixed, even for a small amount of ready mix concrete.

In other embodiments, the fiberglass post 28 can extend above the finished surface, and can support any of a wide variety of suitable overlying structures from the joints above the finished surface.

As indicated above, one of the objectives of the invention is to use wall panels and auxiliary 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.

In some conventional building implementations in areas with substantial seismic activity, reinforced concrete has been used in the foundation of the building. However, even when heavily reinforced with steel, concrete can crack and shatter during seismic activity. In contrast, the walls and wall panels of the invention, built with the same or similar load-bearing requirements successfully resist / tolerate substantially greater seismic loads before structural failure.

Where, for example, seismic activity imposes substantial lateral loads, extending along the length of the wall, a conventional concrete wall cannot deflect, but will instead collapse. Such loads on

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65/103 wooden-framed walls cause such wooden-framed walls to be ruined, for example, to be converted from rectangles to something resembling parallelograms. In contrast, the walls of the invention can deflect outwardly, optionally inwardly, cannot be substantially ruined, and can withstand higher lateral loads than the typically used concrete structures.

In more tropical climates, the external walls above the ground must, in some cases, be built with concrete in order to, among other advantages, inhibit the development of mold. Where strong wind conditions, such as hurricanes and tornadoes, are common, external walls above the ground must, in some cases, be built with concrete to obtain a level of lateral resistance against perpendicularly oriented wind and rain forces, that can resist such forces.

In such situations, as in areas frequented by hurricanes and tornadoes, the wall structures above the ground surface of the invention can be used instead of concrete, while obtaining the lateral strength that can withstand such forces, and at the same time avoiding, for example, water penetration, and other limitations inherent to concrete. Consequently, the wall structures of the invention are considered to be useful in above-ground applications as well as in foundation / below-ground applications.

The Fiber

The reinforcing fiber materials used in products

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66/103 pultrudates of the invention can 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 considered to be acceptable include, without limitation, carbon fibers, Kevlar fibers, and metal fibers such as copper and aluminum. Other fibers can be selected to the extent that their reinforcing properties and other properties satisfy the structural demands of the building panel applications considered in the invention, and provided that the fibers are not prematurely degraded in the use environment considered for the wall panels. , related.

For this purpose, the use of cellulosic fibers is limited to those compositions where the cellulosic fiber can be adequately protected against the harmful effect of moisture reaching the fiber and degrading it. Thus, the use of cellulosic fiber without moisture protection in the invention is generally limited to less than 10% by weight of the total composition of a given structural element, for example, panel, support, or the like. However, where the fiber is impregnated with an adequate amount of resin, and the resin protects the cellulosic fiber from attack by moisture, such composite compositions can be used in concentrations greater than 10% by weight of cellulosic fiber.

The lengths, widths, and shapes in cross section of the fibers can be selected according to the structural demands of the structures in which the panels

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67/103 building or other structures must be used. Similarly, the structures of products manufactured with fiberglass that are incorporated into the panel can be selected according to the structural demands that will be imposed on the panels. Those skilled in the art are able to make such selections.

Figure 5A provides a representative example of a glass specification that can be used to make panels useful in interior wall construction as described here elsewhere. Figure 5A shows the elements / layers of glass fibers arranged around foam blocks 232 in the main projection wall section of the panel and around foam blocks 232A in the posts 123.

Starting from the outer side of the panel, the outermost layer of fiberglass is a 128 g / m ² 260 surface glass veil. Towards the surface veil are the first and second layers 262, 264 of 612 g / m ² unidirectional wicks each with a 255 g / m ² cut filament mat, where the cut filament mat is in each case arranged outwardly towards the outer veil 260 Thus, the fiberglass in the outer layer 236 of the panel is defined by the fiberglass layers 260, 262, and 264.

The fiberglass in the intercostal wefts 250 is a series of 612 g / m ² 266 wicks with a 255 g / m ² 268 cut leg mat, arranged on each side of the wicks between the foam blocks 232 and the wicks.

An intumescent 270 veil of fiberglass mat

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68/103 coated with intumescent material is the innermost fiberglass layer on the panel. An intumescent material is a material that expands, enlarges, forms bubbles, and is typically singed when exposed to the flame and forms a fire retardant insulating barrier between the flame and the material / substrate that supports the intumescent material. A suitable intumescent material is available as TSWB powder from Avtec Industries, Hudson, Massachusetts. TSWB powder can be added to a fiberglass veil by, for example, dispersion coating.

Alternatively, the intumescent material can be added to the resin that will form the innermost layer of the panel.

Next, towards the intumescent veil 270 is a layer 272 of unidirectional wicks of 816 g / m ² with a mat of cut filaments of 255 g / m ² 274, arranged between the wicks and the intumescent veil.

On plumbs 123, then inwardly towards layers 272 and 274 is a layer 276 of 816 g / m ² wicks extending along legs 128, and the end panels 130, of the plumbs adjacent to foam blocks 232A .

Between layers 270, 272 and 274, and foam blocks

232, has a 278 layer of unidirectional wicks of 612 g / m ² , with a mat of cut filaments of 255 g / m ² 280 between the wick layer 278 and the wick layer 274, with the wick layer 278 and the layer of cut filament mat 280 being disposed between foam blocks 232 and 232A on the posts 123. Thus the glass fiber in the inner layer 234 of the panel is defined by layers of

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69/103 fiberglass 270, 272, 274, 278 and 280.

With reference again to Figure 5A on each plumb, one of the legs 128 is aligned with one of the intercostal wefts 250, such that a load transmitted through the respective intercostal weft is readily transmitted to the respective leg 128 of the adjacent plumb.

Now that a specific glass specification has been illustrated for the exemplary wall panel, those skilled in the art can easily design other glass specifications to meet the needs of other implementations of the invention.

The Polymer

The polymer that is used in the pultrusion process, and optionally used as an adhesive to join the structure elements together, can be selected from a wide variety of conventionally available, multi-part curing resin compositions and compositions of thermoplastic resin. Typical reaction curing resin is a two-part liquid where two parts of the liquid are mixed together before the resin is applied to the fiber substrate. Third and additional components can be used in the reaction mixture as desired to obtain the desired level of cure by reacting the resin, as well as to obtain the desired properties in the cured resin. The resin mixture must be sufficiently liquid to be readily applied and spread around a substrate / fiber base sheet in this way to fill all voids in the substrate and / or to flow over, under, around, and through of the fiber composite in a forming process

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70/103 and / or molding. Examples of useful two-part reaction curing resins include, without limitation, epoxy resins, vinyl ester resins, polyester resins, polyurethane resins, and phenolic resins. Examples of thermoplastic resins include thermoplastic polyurethanes, acrylics, polyethylene and other polyolefins. Resin used in pultrusion can also be thermoplastic resins which are embedded in wick that fuse and form the part in the pultrusion matrix.

Those skilled in the art know that each of the reaction-curable resins noted above represent a large family of reactable materials that can be used to make the resulting reaction-cured pultrudated resin structure, and are able to select resin combinations reaction for the uses considered in the invention. Experimental curable resin by suitable reaction is a polyester resin available as XV 2979 through AOC Manufacturing Company, Collierville, Tennessee. In addition, more than two such resins can be mixed to obtain the desired set of properties in the reaction product or process.

Similarly, each of the thermoplastic resins noted above represents a large family of materials that can be used to make the resulting FRP products. Suitable thermoplastic resin, specifically for weft bag molding, is an acrylic resin available as MODAR from Ashland Inc., Covington, Kentucky.

The resin, that is, reaction-curable resin or

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71/103 thermoplastic resin, can be modified by adding filler material to the polymeric composition, in the amount of up to 200 parts of filler material by weight for every 100 parts of polymer, optionally 30 parts of filler material up to approximately 100 parts of filler material per 100 parts of polymer, optionally approximately 40 parts of filler material to approximately 60 parts of filler material per 100 parts of polymer. Approximately 50 parts of filler material for 100 parts of polymer were found to be highly satisfactory. Although several filler materials can be used for the purpose of reducing the cost of the resin component of the resulting panel, alumina trihydrate powder, as conventionally available as a polymeric filler material, has been found to be quite satisfactory in that alumina trihydrate meets the cost containment goal while adding a level of fire retardation. Suitable alumina trihydrate is available from Huber Engineered Materials, Atlanta, Georgia.

For any set of reaction materials or thermoplastic resins that are used in the invention, any conventional additive package can be included such as, for example, and without limitation, catalysts, antioxidants, UV inhibitors, fire retardants, fillers, material intumescent, flow control agents, whether organic, inorganic or polymeric, to perfect the resin application and / or resin curing process, and / or to optimize

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72/103 properties of the finished product such as weather resistance, fire resistance, hardness, shrinkage control, mold lubrication, dyes, filling materials and other desired characteristics.

Each set of two or more materials that can be mixed and reacted to make the resulting resin product, or each thermoplastic composition, has its own processing parameters, such as reaction temperature, catalysts, time required for a curing reaction to occur, extruder temperature, matrix temperature, and the like, together with the respective processing equipment with which the respective resin is effectively processed. In addition, each set of such two or more reaction materials, or each thermoplastic resin composition, develops its own set of physical and chemical properties resulting in the light of curing or plasticizing processes, and molding. Specifically, the physical properties are influenced by the effect of the included fibers and fillers, such that more than two of such reagents, or two or more thermoplastic resins, can be useful in obtaining, in the finished polymer, a desired set of physical properties.

The Polymer / Fiber Composite

In general, dry fiber filaments are used as the fiber base for a pultrusion process. For example, dry fiber substrate, woven cloth, fiber mat and / or wicks are used for structural elements of the invention except wall panels, such structural elements as pillars 28, blocks 30, coverings 58, and

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73/103 any of the supports 48, 60 and 188. Where using a process other than a pultrusion process to form a structural element, sufficient resin is added to the fiber substrate to fill all empty spaces, so there should be no air inclusions , or few air inclusions so as not to have material affecting the chemical or physical stability, or other physical properties, of the structural element being manufactured. In general, the glass / resin ratio is high as can be obtained while leaving no significant, damaging voids in the resulting structural element when the resin is cured.

Given the requirement to minimize empty spaces, and using conventional layer development techniques, the resulting structural layer product, for example, layer 34 or 36, or intercostal wefts 50, or another product, has approximately 30 percent in weight to approximately 65 weight percent of fiberglass, and correspondingly approximately 70 weight percent to approximately 35 weight percent resin. Optionally, the resulting layer is approximately 40 weight percent to approximately 60 weight percent fiber and approximately 60 weight percent to approximately 40 weight percent resin. A typical resulting cross section is approximately 45 weight percent to approximately 55 weight percent fiberglass and approximately 55 weight percent to approximately 45 weight percent resin, optionally approximately 50 weight percent fiber. glass and approximately 50 weight percent resin. Where filling material is

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74/103 used, the weight of the filler material, as well as other resin additives, is considered as part of the resin fraction mentioned above.

According to well-known technology, the number of layers of glass, in combination with the weight of the glass per layer, generally determines the thickness of the resulting layer after the resin-impregnated layer is cured. For example, multiple layers of a 407-1016 g / m ² layer of woven fiberglass cloth can be impregnated to fill the voids, and to thereby obtain a resulting cured structure which is typically between approximately 1 millimeter of thickness and approximately 12.7 mm thick. The greater the number of fiberglass layers that are impregnated, typically the greater the thickness of the resulting cured and impregnated deposit reinforced layer.

With reference to wall panels 14 in which the uprights 123 are in a vertical, upright orientation, the reinforcing glass fibers are predominantly oriented to extend in a vertical direction, for example, from top to bottom, parallel to the uprights. Transverse fibers and / or adjacent layers having transverse fibers, can be used to join the vertical fibers, thereby to provide a relatively lesser degree of resistance contributed by the transversely oriented fibers and to fix the lateral locations of the vertical fibers.

The bottom plate can be of any material that can support the load imposed on the overlying wall panel. A typical bottom plate is, for example, a fiber reinforced pultrusion 12.7 mm thick, which

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75/103 is sufficiently hard and rigid to spread the overlying load to the underlying soil substrate along the length of the panel through, for example, a clean, leveled aggregate stone base. The stone can be a stone

crushed stone or an aggregate stone not crushed. The top plate 20 can be done without limitation, materials reinforced with fibers of glass or others materials reinforced with fibers, resinous, including pultrusions reinforced with fiber of glass, or others

materials such as wood, in the format conventionally used for the top plate, or in a novel format such as that illustrated in 342. It is considered that a plate superior to the conventional wood base serves the purpose, properly, and provides the fixation of the overlying wooden elements such as wooden frame, using conventional fasteners and conventional fastening methods.

The Foam

The purpose of foam 32 can be twofold. First, the foam can contribute to the structural integrity and strength of the building panel structure by being sufficiently rigid, that is, a rigid foam, and sufficiently affixed to the adjacent panel elements, so that the foam contributes significantly to the fixation of the structural layers 34 and 36, and intercostal wefts 50, in their configurations designed under normal load of the panel, either vertical gravitational load, or lateral load such as loads of the lateral terrain in applications below level, and lateral loads caused by wind and / or water in level applications

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76/103 above. Thus, the foam can make a substantial contribution to the dimensional stability of the panel 14.

Second, the foam contributes a substantial thermal insulation property to the construction of the resulting building panel.

In achieving a desired level of thermal insulation while maintaining the foam as a closed, rigid cell material, the foam has a density of approximately 16 kg / m ³ to approximately 192 kg / m ³ , optionally approximately 32 kg / m ³ , at approximately 128 kg / m ³ , optionally approximately 32 kg / m ³ at approximately 80 kg / m ³ . Lighter foams can be used as long as the desired level of thermal insulation is achieved. Although heavier foams can be used, and typically provide a greater increase in structural strength, certain heavier foams can provide less than the desired level of insulation properties

thermal, and are more expensive. In general, foams used in the invention are foams in cell closed, relatively lighter. Foam 32 can to be made of an wide variety of

compositions including, without limitation, extruded polystyrene foam, expanded beads polystyrene foam, rigid urethane foam, phenolic foam, or polyisocyanurate foam. The foam is moisture resistant, preferably moisture proof, and is chemically and physically compatible with the compositions and structures of layers 34 and 36, and intercostal wefts 50. A suitable foam sheet is a 32 kg / m polyisocyanurate foam ³ , available through the Elliot Company, Indianapolis,

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Indiana.

The foam 32 optionally fills all, or substantially all of the spaces between the respective surfaces of the structural layers 34 and 36, and intercostal wefts 50, and is in surface-to-surface contact with the respective layers and intercostal wefts when such layers define the cavities in the which the foam is received. In addition, the foam is adhered to the respective structural layers and intercostal wefts in order to absorb the absolute forces between the foam and the respective structural layers and intercostal wefts.

The foam blocks 32 can be placed in a surface-to-surface relationship with the fiberglass and resin as part of the pultrusion process while the pultrusion profile is being formed and pultruded and before the resin has hardened, so the foam is in surface-to-surface contact with the respective layer precursors and becomes moistened with uncured / plasticized resin. With the foam in contact with the fiber-reinforced layer precursor in process, and moistened by the fiber-reinforced layer precursor, the hardening of the resin when the thermoplastic resin cools, or when the curing resin by reaction polymerizes the foam bonds with the structural layers 34 and 36, and intercostal wefts 50 as appropriate, so that no separate adhesive is necessarily required to bond the foam to the respective structural elements.

Given a typical thickness of the main projection wall section of approximately 7.6 cm, since cavities 196 are filled with light insulating foam, the

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78/103 wall panels of the invention provide thermal insulation factors between layers 34, 36 of approximately R15. An additional factor, for example, R13 can be obtained by installing layers of fiberglass insulation in cavities 131, thereby to obtain a total insulation factor of approximately R28 in the typical walls of the invention, and to obtain thermal insulation properties, far superior to most concrete wall products, even insulated concrete wall products, currently available to the consumer public. Such a superior insulation value can thus decrease heat loss to a substantially greater degree than most foundation wall products currently available to the consuming public.

From the beginning to the end of this teaching, reference was made to the posting of various elements of the building panels to each other. In some cases, mechanical accessories, such as dowels, have been mentioned; such as to fix the upper plate to the support 24 or 24A or 24B. In cases where two elements are attached to each other, and where both elements contain resin components, especially reaction-cured components, curing the resin in any of the structural elements being formed or joined can be used to fix the elements together. another such that no additional adhesive needs to be used. On the other hand, where components are assembled together at the construction site, at least in some cases, the use, for example, of conventional construction adhesives or sealants that are known to be useful in construction projects, is considered.

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An example of using construction adhesive when mounting the foundation wall is to attach the bottom plate to a wall panel. The wall panels of the invention can be transported to the construction site without the top sheet or the bottom sheet and where the materials of the top sheet and the materials of the bottom sheet can be transported to the building site separately, although potentially in the same vehicle. The lower plates and upper plates are then affixed to the wall panels at the construction site, as desired. The bottom plate is typically affixed to the bottom of the wall panel with a construction adhesive, with or without the aid of support 24, and optionally bolts generally extending through the thickness of the wall panel between layers 234 and 236. The plate top can be affixed to the top of the wall panel using supports 24 and pins 139, and / or other support as needed, and optionally in addition, or alternatively, adhesive between the top plate and the top of the wall panel.

Brackets 48, 160 and 170 can be mounted adhesive on the construction panels. Alternatively, where the panels and supports are made using curing resins, the surfaces of the respective parts, including the respective areas of the building panels, can be coated with a supply of curing resin before the parts are assembled, and the parts can then be held together for a sufficient time, under known satisfactory conditions, which result in the curing of the resin, so that curing of the resin develops the necessary level of fixation between the

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80/103 respective parts of the wall.

Likewise, whether through adhesive or through the use of curable resin materials, the plumbs 123, the support brackets 24, 48 and the floor and garage cover supports 188 can be mounted on a wall panel after the panel wall reach the construction site.

It will be understood that any fixation of the support 24 on the internal surface of the wall panel must generally be developed integrally in relation to its required operating resistance before the upper plate or lower plate, as the case may be affixed to the wall panel and apply its nominal load to support 24.

Figures 5, 17, 18 and 19 show cross sections of building panels of the invention in which the inner layer 34, 234 and the outer layer 36, 236 are integral with an intercostal frame of structural reinforcement connection 250. The plumbs 123 are extend from the inner layer 34, 234 inwardly to the end panels 130 on the respective posts. In the examples of Figures 18 and 19, one of the legs 128 in each of the plumbs is an extension of a respective intercostal weave 250, whereby the intercostal weave and the plumb leg function as supports in line with each other, and thus forming a structure of continuous unitary support from outer layer 236 to end panel 130, and extending the full height of the wall panel. Plumbs 123 create a cavity 131 (Figures 17-19) for installing utilities or for adding insulation.

The building panels of the invention can be made by, for example, a continuous pultrusion process or

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81/103 a wet molding process. A pultrusion process is illustrated in Figure 20 in which the cross sections shown in Figures 5 and 17-19 are representative of the product that emerges from the pultrusion matrix. The pultruded product is produced continuously by means of a pultrusion device 97. The pultrusion device 97 receives the programmed glass fiber loads and resin loads, optionally foam block charges 32, and shapes and consolidates these materials in the configuration projected. The pultruded product thus formed and consolidated is cut by means of a mobile cutting saw 98 in convenient lengths that represent the height of a vertical building panel used, for example, in a wall structure.

Referring to Figures 18 and 19, the panel, when pultruded, has a generally continuous male side 216 and a generally continuous female side 218.

Referring back to Figure 20, the panel lengths thus cut travel through the conveyor 100 to a redirect corner conveyor 102, where the cut panels perform a 90 degree turn while maintaining the orientation of the panel, and exit the turning conveyor. moving with a front side edge 104 and a rear side edge 106. When each panel exits the swivel conveyor, the front side edge and / or the rear side edge of the panel is moistened with adhesive on workstation 108 so that the lateral edges, male and female, facing adjacent panels can be joined by adhesive. The side edges, male and female, adjacent of adjacent panels are then

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82/103 pushed / induced together, thereby joining the side edges of the adjacent panels together as shown in Figure 5. When the side edges are joined, a desired level of mechanical compression is applied to the joined side edges, thereby to maintain mechanically the side edge elements in bonded relationship, for example, at work station 110 long enough to obtain structural stability and longevity of the bonding relationship, for example, until the adhesive material is cured.

Downstream of workstation 110, a displacement cutting saw 102 can be used to cut the two panels thus joined to any desired length.

Before or after the saw cut to exact length 112, the plates, top and / or bottom, can be applied on the top and / or bottom of the panel in respective workstations 114, 116. Alternatively, the plates, top and / or bottom, can be applied to the top and / or bottom of one or more panels at the construction site.

The cut ends, top and bottom, are covered by the top and bottom plates, as desired, in the manufacturing process, or before installation at the construction site.

In the modalities where the closed cavities 196 in the pultruded structure are empty as in Figures 16 and 17, all the resistance in the structure is derived from structural elements 234, 236, and 250, and plumbs 123 when present. Thus, structural elements 234, 236 and 250 and plumbs 123 are designed as structural members. The thicknesses of layers 234 and 236, and intercostal wefts

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250, and plumbs 123, can be, for example, and without limitation, from approximately 1 mm to approximately 12.7 mm for building panels that are to be used for typical light or industrial light residential or commercial construction.

Cavities 196 can be used as utility installations as desired. In any of the pultruded structures, cavities 196 can be filled with insulating foam or other known insulating materials, as desired. The stiffness provided by such an insulating material, if any, can be considered when designing the thicknesses of the structural elements 234, 236, and 250 and the layers in the posts 123. Foam can be incorporated into the cavities 196 by feeding previously formed elongated blocks 232 of foam in the pultrusion matrix together with the fiberglass and the resin, so that the resin flows around not only the fiberglass but also the foam, and binds to both, the foam and the fiberglass.

In some embodiments, the foam blocks are already wrapped with one or more layers of glass fibers before being fed in the pultrusion process. In other embodiments, the entire glass fiber is fed to the pultrusion process separate from the foam blocks.

In still other embodiments, the foam is added to the cavities 196 after the resin / fiber composition has been formed and hardened in the pultrusion process. In such cases, a foam-in-place process is used to inject foamy material into cavities 196.

Exemplary structures of lateral edges of the building panels, pultruded, and joints of adjacent panels,

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84/103 are shown in Figures 5, 16 and 17. Figures 5, 18 and 19 show male-female end combinations on building panels 14. Each panel has a male edge 216 and a female edge 218. Figure 16 shows the end joining structure where the two ends 220 of a panel define a first step 222A, 222B and a second step 224A, 224B, each panel having the same end structure at both ends, and all panels having a common end structure. In Figure 16, end 220A of panel 14A is joined with end 220B of panel 14B.

Figure 17 shows the first and second pultruded panel 14A, 14B, similar to the panels illustrated in Figures 5 and 16, including intercostal frames 250. In Figure 17, each panel has a single end 220A and a receiving end 220B. A reinforcement plumb 123 is integral with the receiving end 220B. The single end 220A of the second panel 14B abuts against, and is joined with the receiving end 220B of the first panel 14A when making a wall structure, ceiling structure, or floor structure; and the inner layer 234 of the second panel 14B abuts against and is joined to the surface 226 of the plumb 123 in the adjacent panel 14A, the surface 226 being that surface of the plumb that faces outwards in a building constructed when the panel is used in the construction of an external building wall.

As long as the panels are not cut, the panels can be joined end to end using the end structures that were manufactured as part

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85/103 of the process of initially manufacturing the panel. Where an initially fabricated end structure of a panel is cut, such as at the construction site, the cut end of that panel can be joined to another panel using, for example, an H 140 support (Figure 13A), to make a joint of straight line as shown in Figure 15A.

With reference to Figure 17, the distance between the receiving edge and the simple edge represents the length of a panel 14. In panels using plumbs 123, and where the panels are long enough, plumbs 123 are typically spaced at standardized distances in the industry, parallel to each other, along the length of the panel. Thus, uprights 123 are typically spaced every 40.6 cm (16 inches) or 61 cm along the length of the panel. Where other spacing distances constitute the standard, according to local practice, a corresponding plumb spacing distance is considered.

The invention considers plumbs 123 structured as closed structures, such as a rectangular tube with closed perimeter, which can be mounted on a pultruded wall panel in desired spacing along the length of the wall panel. The invention further considers plumb 123 as a structure plumb 123, for example, as a three-sided rectangular pultruded structure, having opposite flanges on the open side of the tube, where such flanges extend apart from each other and in which the flanges provide mounting structure for mounting the plumb on a wall panel, for example, on layer 34.

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The plumbs 123 can be centered on an intercostal structural reinforcement member 50, 250, as in Figures 5 and 17, or displaced from the structural reinforcement element, with one of the plumb legs operating as an extension of the intercostal member, as illustrated in Figures 18 and 19. In addition, the plumbs 123 can be completely displaced from the intercostal wefts 250.

Figure 21 shows a wall panel that has no intercostal reinforcements, that is, no intercostal frame 50, 250, and no other reinforcement between the inner and outer layers. Figure 21 shows an intermediate layer 39 between the plumbs 123 and a foam board 32BD. The 32BD foam board is generally continuous across the total height and width of the wall panel, and through the total thickness of the wall panel between the middle layer 39 and the outer layer 36. Specifications for the 32BD foam board, including the polymer content, density, stiffness, and the like, are identical to those for foam blocks 32. Specifications for intermediate layer 39, including fiber content, polymer content, polymer selection, layer thickness, and method of making the layers are generally identical to those for layer 34, i.e., layer 39 can be made through the pultrusion process as part of the process of making the remaining elements of the panel.

Figure 21 also shows a reinforcement layer 36R arranged outwardly from outer layer 36 such that outer layer 36 is between reinforcement layer 36R and foam layer 32BD. The specifications for layer 36R in the modalities of Figure 21, including content of

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87/103 fiber, polymer content, polymer selection, layer thickness, and the method of making the layer are identical for layer 36, that is, layer 36R can be made through the pultrusion process as part of the process to make the remaining elements of the panel.

Layers 36R and 39 are optional. Figure 22 illustrates an embodiment where layer 39 is retained, but layer 36R has been omitted. In Figures 22 and 23, the respective layers are represented by individual lines. The structure of Figure 22 includes foam board 32BD, outer layer 36 on an outer surface of the 32BD board, intermediate layer 39 on an inner surface of the 32BD board, inner layer 34 covering the intermediate layer 39, and plumbs 123 between the intermediate layer 39 and the inner layer 34. Layer 39 can be omitted in such a way that the uprights 123 are located directly against the 32BD foam sheet. Figure 22 further illustrates an alternative configuration for the ends, male 216, and female 218, on the panel.

Figure 22 illustrates the spacing of the plumbs in 40.6 cm (16 inches), with the corresponding spacing of the ends, male and female, in order to accommodate the common construction protocol that separates the plumbs in 40.6 cm (16 inches) ) along the length of the wall for the purpose of interfacing the plumbs with the commonly available building materials.

The modalities illustrated in Figure 23 are similar to those illustrated in Figure 22, including the intermediate layer 39, with the addition of the reinforcement T's 46, adjacent to the outer layer 36. While the T's 46 can

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88/103 be made of a variety of hard, rigid, FRP materials, similar in stiffness to layers 34, 36 are considered. In general, T's 46 are affixed to the outer layer 36 in order to absorb and sustain the especially external stresses imposed on the wall panel in the outer layer 36, thereby to direct such stresses away from the outer layer 36 and internally to the inside of the wall panel.

The wall panels of Figures 21, 22 and 23 are conveniently made in pultrusion processes in which the foam sheet is fed to the pultrusion processing equipment after which the respective resin is applied to the foam sheet, resulting in the inherent bonding of the resin to the foam sheet when the resin cures around the sheet. Suitable reinforcing fiberglass structure can be fed simultaneously in the pultrusion process, thereby to collectively position the foam, resin, and fiberglass in relation to each other, and to bond the foam, resin, and the fiberglass to each other during the pultrusion process.

In some embodiments, the fiberglass layers are mounted on the foam sheet before the foam sheet is fed into the pultrusion process.

Where reinforcement T's 46 are used, grooves are optionally formed on the foam sheet, and the T's are mounted on the foam sheet, before the foam sheet is fed to the pultrusion process. Construction adhesive can be used to temporarily or permanently maintain the reinforcement T's on the foam sheet before feeding the foam sheet to the pultrusion process. In

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89/103 In any case, the curing of the resin around the foam sheet, and the flow of the resin into the T grooves, result in the foam sheet being mounted solidly on the panel, mounted solidly on the foam, and the T's being incorporated solidly. in the resulting structure.

Wall panels without plumbs 123, as in Figures 21, 22 and 23, have specific use in some applications above the finished surface, where the strength requirements are less. Wall panels without plumb are also used in applications above the finished surface where thermal insulation requirements are greater than in foundation walls, and / or where utility cavities 131 are relatively less valuable, meaning that a value of greater total insulation can be incorporated into the wall panel when pultruded, by providing a wall panel in which the main projection wall section is sufficiently thick (dimension T) to provide a uniform thermal resistance over the length and height wall totals.

Figure 24 shows an elevation view of a portion of a wall of the invention, including a base 53 on an underlying natural base, a lower plate 16, a wall 10 of the invention, an upper plate 20, and overlying floor 40. Loads L1 and L2 are shown spaced apart and applying downwardly oriented forces on the wall. The L1 and L2 loads represent building loads generated by the overlying building structure. The loads L1 and L2 are intended to represent loads of different magnitude, spaced along the length of the wall, as representations that the loads of

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90/103 different magnitudes are typically imposed on an external building wall at different locations along the length of the wall.

Under each of the loads L1 and L2 in Figure 24, a first cone defining a relatively narrow first angle is defined by the dashed lines, and a second cone defining a relatively larger second angle is defined by solid lines. The relatively narrower and larger angles of the cones under each load are generally intended to represent the relative difference between the load distribution on a concrete wall (narrower angle) and the load distribution on the walls of the invention (larger angle). Thus, Figure 24 illustrates a substantial functional difference between the walls of the invention and the conventional concrete walls. That is, in relative terms, the concrete walls tend to distribute the load over a relatively smaller area while the walls of the invention tend to distribute the load over a relatively larger area. The shaded area with horizontal lines represents a portion of the wall extension where the L1 and L2 loads are supported in part by the lower portion of a wall of the invention while a concrete wall does not have such a load-sharing function with respect to the L1 loads. and L2.

Due to the relative load-sharing features of the concrete walls and walls of the invention, for a given building structure, the building load from that portion of the building that covers the foundation wall, delivered through the building wall.

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91/103 foundation to the base by a wall of the invention, designed to carry such a load, has a load variation along the extension of the base, which is substantially less than the load variation provided through a concrete foundation wall that is designed to carry such an overlying building load. And, in general, the load supplied to the base generally varies by less than approximately 50 percent, typically by less than 25 percent, over any length of 3.04m (10 feet) from the base.

No dimensions are provided in Figure 24, be it wall dimensions or cone angle magnitudes, because the performance of a specific wall depends on the exact specifications of that wall. Thus, Figure 24 shows the general trends of the walls of the invention for a given building structure in relation to the concrete walls designed to deal with a similar building structure.

Another advantage of the wall structures of the invention is that, for a given base model, the wall structures of the invention can carry higher overlying loads on the foundation wall than on the concrete foundation walls.

For example, consider a standard concrete wall 20.3 cm (8 inches) thick and 2.7 meters high, which weighs approximately 1,488 kg per linear meter,

covering a base in 0.6 meters wide where The capacity in charge of ground it's from 14,637 kg per meter square. Given the base in 0.6 meters wide, The

Load capacity of the ground is 8,925 kg per linear meter.

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As the concrete wall weighs 1,488 kg per linear meter, the overlying building structure is limited to no more than 7,438 kg per linear meter.

In comparison, using the same parameters, but replacing the concrete wall at 1488 kg per linear meter with the wall structure of the invention, which is approximately 37-89 kg per linear meter, the overlying building structure can exert as much as at least 8,793 kg per linear meter, an 18 percent increase in the amount of load bearing capacity of the soil that can be derived from the building structure that covers the foundation wall.

Yet another advantage of the walls of the invention is the fact that the variation in the finished height of the foundation wall can be controlled more closely in the walls of the invention than is possible in relation to the finished height of a foundation wall where the wall is built in. site from ready mix concrete, dumped or concrete block walls. That is, even when using highly specialized masons, a variation in height of a finished concrete wall from 12.7 mm to 25.4 mm is very common. Such variations can be attributed, at least in part, to the fact that ready-mix molds are laid manually. Whatever the cause of such variations, this is the experience in the industry.

Such variation is generally transferred to the overlying portions / floors of the construction structure, resulting in unintended structural dimension variations and unintended load distribution variations.

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In comparison, since the wall panels and panels of the invention are, by definition, manufactured, at least in relation to height, in a fixed location manufacturing facility, the variation in height can be substantially attenuated, thereby substantially attenuating such variations in unintended structural dimensions and variations in unintended load distribution. In general, the wall panels of the invention, when installed in buildings, can vary in height by a length of 12.2 m (40 feet) of the wall panel less than 12.7 mm, optionally no more than 6, 3 mm, optionally less than 3.3 mm, and typically not more than approximately 1.6 mm.

Among the requirements of the wall structure element is that the materials in the wall structure cannot be sensitive to, susceptible to substantial water degradation or any inclusions commonly found in water, whether they are dissolved minerals or organic materials such as forms of life that live in the compositions or transform the compositions of the fibers. That is, the materials cannot be subject to degradation by water or anything in the water, to the extent that such degradation jeopardizes the structure's ability made from such building panels, to provide the necessary compressive strength to support the overlying building loads, and the bending loads imposed by the underground forces, and external forces above the finished surface.

Consequently, wall elements typically do not include corrugated wood fiber structures, do not

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Coated 94/103 commonly referred to as corrugated cardboard structures, or any other fibers whose strengths are substantially affected by moisture or wet steam. Nor do wall elements typically include any inclusions that are substantially affected by materials that may exist in the moisture found in or around the soil adjacent to a building structure. In addition, fibers or other inclusions cannot be susceptible to insect infestation, or any other degradation factors. Thus, fibers or other inclusions are generally inorganic materials that are not affected deleteriously, that is, whose useful properties are not severely degraded by the environment in which the wall panels are used, during the expected life of such wall panels; whose service life generally adapts to local industry standards.

Although a pultrusion process has been described here to make the wall panels of the invention, panels 14 can be made by other known manufacturing processes such as wet bag process, and optionally bag infusion processes. Wet bag processes are especially advantageous in some of the panel configurations.

In any of the embodiments of the invention, one or more gel coatings can be applied to the panel structure on one or both internal and external surfaces.

Whatever materials are used for the reinforcing fiber, foam, resin, or all such elements, including UV inhibitors, fire retardants, any

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95/103 fillers, any intumescent material, any smoke toxicity suppression agent, any smoke generation suppression agent, any wetting agent, any fluidity optimizers, or any other additives, are chemically and physically compatible with all other elements with which they will be in contact, in such a way that no harmful chemical or physical reaction occurs between cooperating materials that are used in the manufacture of the inventive wall systems.

One of the substantial advantages 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 a concrete structure on the housing walls above the finished surface. Experience has shown that hurricane force winds force rain through such concrete wall structures in order to cause substantial water damage even when the building structure itself is not damaged.

In comparison, the wall structures of the invention are essentially waterproof, and such waterproofing characteristics are unaffected by hurricane-driven rain. The outer layer 36, 236 is itself waterproof. Although layer 36, 236 is quite resistant to water penetration, even if the outer layer 36, 236 is broken, foam 32 is waterproof in that the individual cells of foam 32 are typically closed cells. If the foam layer is also broken, the inner layer

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96/103 is also waterproof. In any case, any breaking force must penetrate multiple waterproof layers, at least two of which are substantially resistant layers when considered in the light of the types of forces that are typically imposed on buildings by weather or other typical external loads. Structures that do not include foam are substantially similarly effective barriers to water penetration.

With regard to the connection between the bottom of the wall panel and the lower plate, such connection can be filled with curable resin as discussed previously here, with adhesive, with caulking, or with other barrier material, thereby blocking any penetration of water at the junction between the wall panel and the bottom plate.

Similarly, vertical joints in the foundation wall can be closed to water penetration by applying curable resin, adhesive, caulking, other waterproof coatings to the joint, as well as using H 140 supports. In addition, as mentioned here in elsewhere, adhesives, resins, and the like can be applied to the building panels and / or to the various supports before the supports are applied to the respective building panels, thereby to provide additional waterproofing characteristics for the finished foundation wall, or wall above the finished surface.

Building panels of the invention are used in several light residential, commercial and industrial construction applications. The strength and other specifications of a given wall panel are specified according to

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97/103 with the loads to be imposed during the predicted useful life of the building.

Wall structures of the invention have application in, and as, for example, and without limitation, construction of foundation walls; frost walls, for example, in buildings without a basement; home-based curtain walls, manufactured; floor systems; roof systems, roof systems; exterior walls above the finished surface; curtain walls as in elevated construction replacing concrete block; and exterior walls in areas that use masonry exteriors, such as coastal construction. Although the specification and drawings were concentrated on the foundation walls, the principles disclosed here apply in the same way to other uses of panels and accessories of the invention.

Various accessories and parts can be used with projects that use the walls of the invention, for example, and without limitation, pillars to support beams / supports, fiber reinforced pillars that optionally include structural top and base, pillar blocks, inner corner supports , outer corner brackets, H channel brackets, top plate connectors, garage floor shelves, support brackets, garage and floor cover brackets, service door openings, garage door openings, protection transitions freezing, and plumb profiles.

In addition, fiber and resin repair kits, suitable for use in the repair of a damaged building panel, corner wall connectors, complete transition from basement to garage, can be mentioned.

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98/103 freeze protection returns, fixing upper and lower plates, together with potential transport advantages where upper and lower plates and / or other elements are affixed to the construction site, beam receptacles, pillar blocks at the base for load distribution, and window openings. Fasteners can also be mentioned to apply exterior product and to provide connection with other parts of the building. Such fasteners can be, for example, and without limitation, metal, or fiber-reinforced polymer composite. Various accessories can be affixed to the wall structure using conventionally available adhesives and / or mechanical fasteners such as screws and bolts, for field applications.

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

The building panels of the invention can be cut, using conventional tools commonly available at a construction site, to meet the needs of handwork. For example, a panel can be cut to the exact size. A window opening can be cut out. A door opening can be cut out. Utility perforations of the foundation wall can be cut, such as for fresh air intake from the oven or flue gas discharge, or the like, or such utilities can be installed in the cavities 131 between the plumbs 123 and towards the layer internal 34.

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Advantages of the invention include, without limitation, a lower composite sheet that has the potential to provide a wider use space for the underlying soil than the projected area of the wall panel, to distribute the building's overlying weight. The bottom plate can be applied on site or off site. The wall structures of the invention are light compared to the concrete structures they replace. The wall structures of the invention are waterproof, versatile, resistant to mold, resistant to termites, and resistant to rot. The substantial polymeric component of the wall frame compositions of the invention provides a desired level of barrier according to existing building codes so that the conventional polymeric layer used outside the foundation wall is not necessary, and can be omitted together corresponding savings in material and labor costs.

The typical wall structures of the invention can be installed with only manual labor or minimal equipment, and do not require the presence of any large machines at the construction site for the purpose of installing a base, a foundation wall, or an above-the-surface wall finished, no ready mix trucks, no form trucks, and just a light duty crane to install the building panels.

The invention does not consider larger wall panels, for example, thicker, taller, and / or longer, which can weigh at least 363-907 kg or more. Additionally, where a wall, or ceiling panel, is

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100/103 being lifted above the ground floor, a light-duty crane of adequate weight, such as for lifting, for example, up to approximately 1587 kg, facilitates such a higher installation.

The wall structures of the invention can be installed in some stations and in all climatic conditions, as long as the excavation can be carried out to a suitable lateral support base. The panels of the invention are environmentally friendly. The panels of the invention are consistent with the requirements for qualification with Green buildings and / or Energy Star buildings, so buildings made with the building panels of the invention may qualify for such categories. No humidity test is required. When the foundation walls are in place, the interior of the space thus enclosed is ready to be finished. HVAC cavities are available between plumbs 123 as, for example, in spacing 131. Plumbing and electricity devices can also be installed through walls easily because the walls are easily drilled or cut at the construction site, again between plumbs 123, optionally inside the plumbs 123.

Construction panels can be repaired more easily than concrete. The openings can be cut more easily than with concrete. Wall changes can be made more easily than with concrete. Any typical wall height can be achieved with an easy cutting process. The building panels can be installed on an aggregate stone base, so that no pouring of a concrete base is

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101/103 required. Thus, the lower level wall of the building can be completed without the need for any ready mix concrete at the construction site.

The wall structures of the invention have multiple desirable properties, including that of being fire resistant where fire retardant ingredients are included in the resin formulation, or when intumescent material is used in layer 34, being a suitable barrier to ultraviolet rays, providing good sound attenuation, being generally free from insect infestation, being generally not susceptible to infestation by rotting-generating organisms, being a good barrier to water, including being an adequate barrier to heavy rain, and being a good barrier for transmission of gas.

The wall structures of the invention are resistant, durable, and have very favorable expansion and contraction ratings compared to the concrete they replace. The 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 construction site. Building panels can be mass produced and do not have to be of a specific design such as, for example, known wall systems, which are produced off-site, and transported to the construction site as prefabricated wall systems . Wall, ceiling, roof and floor structures of the invention can be installed in places where it is difficult to obtain ready mix concrete supply, such as

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102/103 as in islands, areas with weight restriction, in high curtain walls, and the like.

Although the invention has been described with respect to several modalities, it should be understood that this invention is also capable of a wide variety of additional modalities and other modalities within the spirit and scope of the appended claims. Thus, the wall panels and walls of the invention can be used for a variety of implementations, which can suggest thicker or stronger walls, to obtain performance requirements of the walls. Other implementations may suggest thinner walls, or weaker walls, for cost effectiveness. Such walls may or may not include plumbs 123, intercostal frames 50, 250, or T's 46. In light of the invention disclosed here, those versed in construction techniques are now able to design such walls according to the needs of their building projects, specifics. All other such implementations are considered here.

Those skilled in the art will see that certain modifications can be made to the equipment and methods disclosed herein with respect to the illustrated modalities, without departing from the spirit of the present invention. And although the invention has been described above with respect to the preferred embodiments, it will be understood that the invention is adapted to various rearrangements, modifications, and changes and that all such arrangements, modifications and changes are intended to be within the scope of the appended claims.

In the extent to which the following claims use language of means plus function,

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103/103 intends to include them; or in this specification; anything that is not structurally equivalent to what is shown in the modalities revealed in the specification.

Claims (10)

1. Polymeric structural building panel reinforced with fiber (14, 14A, 14B, 14C), having a height that extends between an upper and a lower part of the building panel (14, 14A, 14B, 14C), a length , and a thickness, all defined when the building panel (14, 14A, 14B, 14C) is in a vertical use orientation, the aforementioned structural building panel (14, 14A, 14B, 14C) is characterized by comprising: (a) a first fiber-reinforced structural polymeric outer layer (36, 236) defining an outer surface (56) of said building panel; (b) a second fiber-reinforced structural polymeric inner layer (34, 234) spaced from said first outer layer (36, 236) by a first distance and defining an inner surface (57) of said building panel; (c) a plurality of fiber-reinforced polymeric structural reinforcement webs (50, 250), spaced from each other, and extending from the first fiber-reinforced polymeric outer layer (36) to the aforementioned second polymeric reinforced inner layer fiber (34, 234), a given fiber reinforced polymer reinforcement web (50, 250) having a defined length along the height of said building panel (14, 14A, 14B, 14C); and (d) a plurality of polymeric posts reinforced with structural reinforcing fiber (23, 123) spaced from each other along the length of said panel. Petition 870190064002, of 07/08/2019, p. 19/45 2/6 building (14, 14A, 14B, 14C) and extending along the height of the aforementioned building panel (14, 14A, 14B, 14C), a certain plumb (23, 123) having an upper part corresponding to the part top of said building panel (14, 14A, 14B, 14C) and a lower part corresponding to the bottom of said building panel (14, 14A, 14B, 14C), a first end adjacent to said second inner layer (34, 234) and extending away from both the aforementioned second inner layer (34, 234) and first outer layer (36, 236) along the first and second legs (128) to an end panel (130), said plumb (23, 123) extending in a common direction with one of the aforementioned structural reinforcement webs (50, 250), in which, an overlying load applied on the top of the aforementioned building panel (14, 14A, 14B, 14C) passes downwards from the top of a respective plumb (23, 123), along the length of said plumb (23, 123), towards the bottom of said plumb (23, 123). 2. Polymeric structural building panel reinforced with fiber (14, 14A, 14B, 14C), according to claim 1, characterized in that the aforementioned posts (23, 123) extend a distance from the aforementioned second inner layer (34, 234) sufficient to cause deflection of the building panel (14, 14A, 14B, 14C) under nominal load such that the deflection of said building panel (14, 14A, 14B, 14C) is limited to no more than Deflection = L / 240, where L is the height from the top to the bottom of the Petition 870190064002, of 07/08/2019, p. 20/45 3/6 edification (14, 14A, 14B, 14C), and the deflection and L are expressed in a common unit of measurement. 3. Polymeric structural building panel reinforced with fiber (14, 14A, 14B, 14C), according to claim 1 or 2, characterized in that the aforementioned plumbs (23, 123) extend a distance from the aforementioned second internal layer (34, 234) sufficient so that, when the aforementioned building panel (14, 14A, 14B, 14C) is incorporated into a building structure and subjected to an overlying building load, the aforementioned building panel (14, 14A, 14B, 14C) deflects between the upper and lower part of the building panel (14, 14A, 14B, 14C), towards the aforementioned first outer layer (36). 4. Polymeric structural building panel reinforced with fiber (14, 14A, 14B, 14C), according to any one of claims 1 to 3, characterized by the fact that: said first fiber-reinforced structural polymeric outer layer (36, 236) comprising a first layer (262) of unidirectional glass fiber substrate in which the fibers of said first layer (262) are oriented upwards in combination with a resin composition; said second fiber-reinforced structural polymeric inner layer (34, 234) comprising a second layer (278) of unidirectional glass fiber substrate wherein fibers of said second layer are oriented upwards, in combination with said composition of resin; Petition 870190064002, of 07/08/2019, p. 21/45 4/6 said one or more structural reinforcement webs (50, 250) comprising a plurality of structural reinforcement webs (50, 250), each comprising a glass fiber substrate (266) disposed between said internal layers (34 , 234) and external (36, 236), collectively in combination with the aforementioned resin composition, the aforementioned first (36, 236) and second (34, 234) structural polymeric layers reinforced with fiber, in combination with the reinforcement wefts (50, 250), defining spaces between them in each occurrence of the respective reinforcement frames (50, 250); and said second inner layer (34, 234) of unidirectional glass fiber extending between said structural reinforcement wefts (50, 250) and said plumbs (23, 123), a third layer (272) of glass fiber unidirectional in which fibers in said third layer are oriented upwards, extending around said plumbs in said legs (128) and said end panels (130), a fourth layer (276) of fiberglass wicks being arranged inwardly on each of the said plumbs from said third layer (272) of fiberglass, in combination with said resin composition. 5. Polymeric structural building panel, reinforced with fiber (14, 14A, 14B, 14C), according to any one of claims 1 to 4, characterized in that it also comprises foam blocks (32, 232) filling the spaces between the wefts reinforcement (50, 250) and the inner (34, 234) and outer (36, 236) layers. 6. Polymeric structural building panel, Petition 870190064002, of 07/08/2019, p. 22/45 Fiber reinforced 5/6 (14, 14A, 14B, 14C) according to any one of claims 1 to 5, characterized in that the aforementioned second inner layer (34, 234) further comprises an intumescent veil (270) and wherein each of the aforementioned first (262) and second (278) fiberglass layers is accompanied by an adjacent cut filament mat layer (280). 7. Polymeric structural building panel, reinforced with fiber (14, 14A, 14B, 14C), according to any one of claims 1 to 6, characterized by the fact that the mentioned plumbs (23, 123) extend towards within the said inner layer (34, 234) a distance greater than the first distance. 8. Polymeric structural building panel, reinforced with fiber (14, 14A, 14B, 14C), according to claims 5, characterized by the fact that the blocks foam (32, 232) are fully connected with The combination of layers in fiber glass and composition in resin in inner layers (34, 234) and external (36, 236) and in the wefts reinforcement structural (50, 250). 9. Structural external wall (10) in a building, characterized by comprising a polymeric structural building panel reinforced with vertical fiber (14, 14A, 14B, 14C), as defined in any one of claims 1 to 8, the aforementioned panel building covering a base (55), the aforementioned first (36, 236) and second (34, 234) layers being adapted, configured and positioned to distribute a load directed in the overlying direction, applied at the top of the aforementioned building panel (14, 14A, 14B, 14C), as well Petition 870190064002, of 07/08/2019, p. 23/45 6/6 delivering the cargo overlying said base (55) at the bottom of said building panel (14, 14A, 14B, 14C), such that the cargo delivered to said base (53, 55) varies less than 50 % over any length of 5 3.04 m (10 feet) from the bottom of the aforementioned building panel (14, 14A, 14B, 14C). Structural external wall (10) in a building, according to claim 9, characterized in that it comprises a structural polymeric building panel 10 reinforced with vertical fiber (14, 14A, 14B, 14C), said structural external wall containing a sufficiently high fraction of fiber to enable the consistency of height dimension to be achieved, in which a height variation corresponding to a height variation 15 above that of a length of 12.19 m (40 feet) of the aforementioned building panel ( 14, 14A, 14B, 14C) is not greater than 6.4 mm (0.25 in).