Structural building panels and panel components, panel assemblies, methods of making, and methods of using

The fiber-reinforced polymeric structural building panel as in 1, said building panel further comprising a plurality of foam block clusters disposed between said inner layer and said outer layer, at least one said foam block cluster reflecting having been fabricated separate from fabrication of said main body, each said foam block cluster comprising a plurality of foam blocks, each said foam block, in a given said foam block cluster, having a top, a bottom, a left side, and a right side, said building panel, when installed in an upright orientation, having a length and a height, and a thickness defined between said inner layer and said outer layer, a given said foam block, in a respective said foam block cluster, having a length extending along the height of said building panel, a width extending along the length of said building panel, and a thickness extending along the thickness of said building panel, a resin flow medium being disposed between respective opposing pairs of next adjacent ones of said foam blocks, forming intercostal precursors, at least one respective said resin flow medium and said facing next adjacent foam blocks in each said intercostal precursor reflecting having been wetted with resin before the respective foam blocks and the respective said resin flow medium are brought into engaging relationship with each other in the process of fabricating said block cluster, said block cluster being devoid of any mechanical keeper.

A fiber-reinforced polymeric structural building panel having a length, a top and a bottom, and comprising:

• (a) as a first component of said building panel, a main body, fabricated in a first fabrication process and comprising
• (i) an outer fiber-reinforced polymeric layer, said outer fiber-reinforced polymeric layer comprising a first set of fibers in a first reaction-cured resin composition, said outer fiber-reinforced polymeric layer defining a first outermost surface of said main body;
• (ii) an inner fiber-reinforced polymeric layer, said inner fiber-reinforced polymeric layer comprising a second set of fibers in a second reaction-cured resin composition, said inner fiber-reinforced polymeric layer defining a second outermost surface of said main body, opposite the outermost surface;
• and
• (b) as a second component of said building panel, a plurality of load-bearing studs, spaced along the length of said main body and extending, from said inner fiber-reinforced polymeric layer, away from the second outermost surface, including away from said main body, said studs extending along the height of said building panel between the top and the bottom of said building panel, at least one of said studs being mounted to the second outermost surface of said main body,
• a given said stud comprising first and second end walls (126), and first and second legs (128), said end walls and said legs collectively defining a stud cross-section having a plurality of corners (88), wherein thickness of at least one said end wall or leg is relatively thicker adjacent a said corner (88), and relatively thinner at a mid-portion (45) of the respective end wall or leg between respective said stud corners.