Multi-layer panels for modular vault structure

A multi-layered panel for a vault structure having upper and lower spaced horizontal edges, spaced right and left vertical side edges and opposing inner and outer spaced parallel major face surfaces comprising:

• a first panel layer, a second panel layer, and a solid intermediate layer, the first and second panel layers each juxtaposed in solid-to-solid contact with said solid intermediate layer, each panel layer and intermediate layer generally coextensive with a major face surface of the panel;
• a first plurality of nails extending through one major face surface and into at least one of said panel layers, and a second plurality of nails extending through the other major face surface and into at least another of said panel layers, the nails of the first and second plurality of nails extending into the panel layers angled non-perpendicularly to the planes of the major face surfaces to create opposing first and second grids of angled nails within the panel layers, the first grid being offset from the second grid such that the nails of the first grid extend into panel gads between adjacent nails of the second grid and the nails of the second grid extend into panel gaps between adjacent nails of the first grid to reduce the effective size of the gaps in the panel between the nails over generally the entire panel;
• an anchoring structure between said first panel layer and said second panel layer, openings formed in at least one of said panel layers proximate said structure, said anchoring structure positioned proximate at least one of said panel edges and comprising at least one elongated bar, said elongated bar having at least one threaded hole therein for receiving threaded securing screws so that when a batten is placed over the opposing edges of adjacent panels to hold together the panels joined to form a vault structure, securing screws may be inserted through openings in the batten and through said openings in the at least one panel layer and threaded into the elongated bar to provide a strengthened seam between adjacent vault panels;
• whereby the penetration resistance of the seam is enhanced because the securing screws are secured by the elongated bar and are not held only by the panel layers.

A method for making a multi-layered panel for a vault structure having upper and lower edges, spaced right and left vertical side edges and opposing inner and outer spaced parallel major face surfaces comprising the steps of:

• disposing a first plurality of boards in a first direction and adjacent to one another to form a first panel layer;
• disposing at least one additional plurality of boards on top of the first plurality of boards to form a second panel layer which overlies the first panel layer;
• the boards of the second panel layer being disposed adjacent to one another and in a direction perpendicular to the first plurality of boards;
• positioning a solid intermediate layer between the first and second panel layers such that the panel layers are each juxtaposed in solid-to-solid contact with said solid intermediate layer;
• placing an anchoring structure between said first panel layer and said second panel layer proximate at least one of said panel edges and proximate openings formed in at least one of said panel layers, the anchoring structure comprising at least one elongated bar having at least one threaded hole therein for receiving threaded securing screws so that when a batten is placed over the opposing edges of adjacent panels to hold together the panels joined to form a vault structure, securing screws may be inserted through openings in the batten and through said openings in the at least one panel layer and threaded into the elongated bar to provide a strengthened seam between adjacent vault panels;
• driving a first plurality of nails into the panel such that each nail penetrates at least two adjacent layers, the nails of the first plurality being driven into one major face surface of the panel angled non-perpendicularly to the plane of the face surface to create a first grid of angled nails within the layers of the panel,
• driving a second plurality of nails into the panel such that each nail penetrates at least two adjacent layers, the nails of the second plurality being driven into the other major face surface of the panel angled non-perpendicularly to the plane of the other face surface to create a second grid of angled nails, the second grid being offset from the first grid and opposing the first grid such that the nails of the first grid extend into panel gaps between adjacent nails of the second grid and the nails of the second grid extend into panel gaps between adjacent nails of the first grid to reduce the effective size of the gaps in the panel between the nails over generally the entire panel;
• whereby the penetration resistance of the seam is enhanced because the securing screws are secured by the elongated bar and are not held only by the panel layers.