High strength composite wall panel system

A composite wall panel, comprising:

• a first layer of molded structural material;
• a second layer of molded structural material;
• an insulating foam layer disposed between the first and second molded structural layers, the foam layer including a first major side in contact with the first layer of molded structural material and a second major side in contact with the second layer of molded structural material, the first and second major sides of the insulating foam layer each having at least one groove, each groove having at least one groove shoulder;
• and
• at least one connector configured to anchor the first and second layers of structural material to the insulating foam layer;
• wherein the first and second layers of molded structural material extends into the grooves and under the groove shoulders to form a mechanical engagement between the insulating foam layer and the first and second layers of molded structural material.

A composite wall panel, comprising:

• a first layer of molded structural material;
• a second layer of molded structural material;
• an insulating foam layer disposed between the first and second molded structural layers, the foam layer including a first major side in contact with the first layer of molded structural material and a second major side in contact with the second layer of molded structural material, the first and second major sides of the insulating foam layer each having at least one groove, the at least one groove having a dovetail cross-sectional shape;
• and
• at least one connector configured to anchor the first and second layers of structural material to the insulating foam layer;
• wherein the first and second layers of molded structural material extend into the dovetail shape of the grooves to form a mechanical engagement between the insulating foam layer and the first and second layers of molded structural material.

A method of manufacturing a composite wall panel, comprising:

• providing a first layer of unhardened structural material;
• placing an insulating foam layer in contact with the first layer of unhardened structural material such that a first major side of the insulating foam layer is in contact with the first layer of unhardened structural material, the insulating foam layer having a second major side, wherein the first and second major sides of the insulating foam layer each have at least one groove, the grooves having at least one groove shoulder;
• inserting at least one connector through the second major side of the insulating foam layer such that a penetrating segment of the connector resides within the first layer of unhardened structural material and a trailing segment extends from the second major side of the insulating foam layer;
• placing a second layer of unhardened structural material in contact with the second major side of the insulating foam layer such that the trailing segment of the connector extending from the second major side resides in the second layer of unhardened structural material, wherein the first and second layers of unhardened structural material flows into the grooves and under the groove shoulders to form a mechanical engagement between the insulating foam layer and the first and second layers of unhardened structural material;
• and
• allowing the first and second layers of unhardened structural material to harden.