# US 12,006,699 B2 · Wall panel > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,006,699 B2 - Document ID: US12006699B2 - Status: Granted - Kind: B2 - Application number: 18/339,494 - Filed: 2023-06-22 - Published: 2023-10-19 - Granted: 2024-06-11 - Earliest claimed: 2012-09-27 - Assignees: Ddp Specialty Electronic Materials US, LLC - Applicants: DDP Specialty Electronic Materials US, LLC. - Inventors: Charles David Taylor, Jr.; Paul Addison Brown; Berthold Mueller; Randal Scott Hoffner; Stewart Mcintyre Adams - Web page: https://patentgrep.com/patent/US12006699B2 ## CPC - E04F 13/0875: {having a basic insulating layer and at least one covering layer} - B32B 3/085: {spaced apart pieces on the surface of a layer} - B32B 7/08: by mechanical means - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 13/02: with fibres or particles {being present as additives in the layer} - B32B 13/12: of synthetic resin - E04C 2/04: of concrete or other stone-like material; of asbestos cement; {of cement and other mineral fibres}(E04C2/26 takes precedence; material or manufacture B28, C04) - E04F 13/075: for insulation or surface protection, e.g. against noise or impact {(not used; for insulation, e.g. against noise E04B1/00)} - E04F 13/077: composed of several layers, e.g. sandwich panels (E04F13/075 takes precedence){(not used, see E04F13/0866)} - E04F 13/0832: {without load-supporting elongated furring elements between wall and covering elements} - E04F 13/0862: {composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid} - E04F 13/0866: {composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence)} - E04F 13/0873: {the visible surface imitating natural stone, brick work, tiled surface or the like (E04F13/105, E04F13/123, E04F13/147, E04F13/165, E04F13/185 take precedence)} - E04F 13/14: stone or stone-like materials, e.g. ceramics {concrete,}; of glass {or with an outer layer of stone or stone-like materials or glass (E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00)} - E04F 13/165: {with an outer layer imitating natural stone, brick work, tiled surface or the like} - E04F 13/185: {with an outer layer imitating natural stone, brick work, tiled surface or the like} - B32B 2260/044: Water-setting substance, e.g. concrete, plaster - B32B 2262/101: Glass fibres - B32B 2607/00: Walls, panels - E04C 2/288: composed of insulating material and concrete, stone or stone-like material - E04C 2002/007: {Panels with the appearance of a brick wall} - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) ## Abstract The invention is related to a method of manufacturing a wall panel and a wall panel system. The method includes: forming a glass-fiber reinforced rigid magnesium oxide layer including the steps of: pouring or injecting a slurry of uncured magnesium oxide into a mold, embedding glass fiber reinforcing material therein, and curing the magnesium oxide to obtain the glass-fiber reinforced rigid magnesium oxide layer having a first side and a second side; applying, to the second side of the rigid magnesium oxide layer, an insulation layer, the insulation layer comprising a foam; and applying to the first side of the rigid layer a veneer layer. ## Claims ### Claim 1 A method of manufacturing a wall panel, the method comprising: forming a glass-fiber reinforced rigid magnesium oxide layer including the steps of: i) pouring or injecting a slurry of uncured magnesium oxide into a mold, ii) embedding glass fiber reinforcing material therein, and iii) curing the magnesium oxide to obtain the glass-fiber reinforced rigid magnesium oxide layer having a first side and a second side; applying, to the second side of the rigid magnesium oxide layer, an insulation layer, the insulation layer comprising a foam; and applying to the first side of the rigid layer a veneer layer. ### Claim 2 (depends on 1) The method according to claim 1, wherein the glass fiber reinforcing material is configured to be the principal load carrying member of wall panel. ### Claim 3 (depends on 1) The method according to claim 1, wherein the insulation layer has a uniform thickness and an insulation factor greater than or equal to R7 and less than or equal to R21. ### Claim 4 (depends on 1) The method according to claim 1, wherein the veneer layer is brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, vinyl, or paint. ### Claim 5 (depends on 4) The method according to claim 4, wherein the veneer layer functions as a water-resistive barrier. ### Claim 6 A method of forming a wall panel system for a building structure, the method comprising: providing a plurality of wall panels, each of the plurality of wall panels comprising: a rigid magnesium oxide layer having a first side and a second side, the rigid magnesium oxide layer having glass fiber reinforcing material embedded therein; and a foam layer on the second side of the rigid magnesium oxide layer; and securing each of the plurality of wall panels to a structural element; wherein the wall panel system further comprises an applied veneer layer on the first side of the rigid magnesium oxide layer; and wherein the seams are sealed between the respective wall panels. ### Claim 7 (depends on 6) The method according to claim 6, wherein the seams are sealed with a sealing compound. ### Claim 8 (depends on 6) The method according to claim 6, wherein the veneer layer is applied to overlap the seams between respective wall panels. ### Claim 9 (depends on 6) The method according to claim 6, wherein the veneer layer is brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, vinyl, or paint. ### Claim 10 (depends on 6) The method according to claim 6 wherein the veneer layer functions as a water resistive barrier. ### Claim 11 (depends on 6) The method according to claim 6, wherein the glass fiber reinforcing material is configured to be the principal load carrying member of wall panel. ### Claim 12 (depends on 6) The method according to claim 6, wherein the insulation layer has a uniform thickness and an insulation factor greater than or equal to R7 and less than or equal to R21. ### Claim 13 (depends on 6) The method of claim 6, wherein the rigid magnesium oxide layer is a poured, injected, press-molded, extruded, vibration cast, sprayed, or slip formed layer.