Prefabricated composite building panel with fire barrier

A method of manufacturing a building panel comprising:

• providing a horizontal, gererally planar mold having a plurality of receptacles each for receiving a respective one of a plurality of rigid facing elements so as to arrange the facing elements with front faces thereof in a common horizontal plane in a pattern defining spaces between side edges of at least some of the facing elements and side edges of adjacent ones of the facing elements;
• placing a facing element in each of the receptacles;
• applying into the mold a layer of cementitious material so as to fill in at least the spaces between the facing elements and thinly cover the rear face of the facing elements and to engage portions of support strips which are in contact with the cementitious material;
• the cementitious material having setting characteristics so as to set to a rigid condition to form a substantially rigid surface exposed in the mold;
• placing the support strips into the mold before the cementitious layer sets to its rigid condition, the support strips engaging the cementitious material and some of the facing elements;
• applying a support panel over the mold so as to leave a space between the exposed surface of the cementitious layer and the support panel;
• and
• after setting of the cementitious layer, injecting a cellular polymeric material into the space between the exposed surface of the cementitious layer and the support panel to form a foamed rigid sheet of the polymeric material filling the space, the sheet bonding to the exposed surface of the cementitious layer substantially without penetration into the cementitious layer, the sheet also engaging the support strips and the support panel.

A method of manufacturing a building panel comprising:

• providing a horizontal, generally planar mold having a plurality of receptacles each for receiving a respective one of a plurality of rigid facing elements so as to arrange the facing elements with front faces thereof in a common horizontal plane in a pattem defining spaces between side edges of at least some of the facing elements and side edges of adjacent ones of the facing elements;
• placing a facing element in each of the receptacles;
• applying into the mold a layer of a cementitious material so as to fill in at least the spaces between the facing elements and thinly cover the rear face of the facing elements, the cementitious material having setting characteristics so as to set to a rigid condition to form a substantially rigid surface exposed in the mold;
• placing support strips into the mold before the cementitious layer sets to its rigid condition, the support strips engaging the cementitious material and some of the facing elements;
• applying a support panel over the mold so as to leave a space between the exposed surface of the cementitious layer and the support panel;
• and
• after setting of the cementitious layer, injecting a cellular polymeric material into the space between the exposed surface of the cementitious layer and the support panel to form a foamed rigid sheet of the polymeric material filling the space, the sheet bonding to the exposed surface of the cementitious layer substantially without penetration into the cementitious layer, the sheet also engaging the support strips and the support panel;
• wherein the cementitious layer also covers the rear surface of at least some of the facing elements, so as to define a layer portion between the facing elements and the front face of the sheet.

A method of manufacturing a building panel comprising:

• providing a horizontal, generally planar mold having a plurality of receptacles each for receiving a respective one of a plurality of rigid facing elements so as to arrange the facing elements with front faces thereof in a common horizontal plane in a pattern defining spaces between side edges of at least some of the facing elements and side edges of adjacent ones of the facing elements;
• placing a facing element in each of the receptacles;
• applying into the mold a layer of a cementitious material so as to fill in at least the spaces between the facing elements and thinly cover the rear face of the facing elements, the cementitious material having setting characteristics so as to set to a rigid condition to form a substantially rigid surface exposed in the mold;
• and wherein the cementitious layer contains a fire-retardant additive;
• placing support strips into the mold before the cementitious layer sets to its rigid condition, the support strips engaging the cementitious material and some of the facing elements;
• applying a support panel over the mold so as to leave a space between the exposed surface of the cementitious layer and the support panel;
• and
• after setting of the cementitious layer, injecting a cellular polymeric material into the space between the exposed surface of the cementitious layer and the support panel to form a foamed rigid sheet of the polymeric material filling the space, the sheet bonding to the exposed surface of the cementitious layer substantially without penetration into the cementitious layer, the sheet also engaging the support strips and the support panel.

A method of manufacturing a building panel comprising:

• providing a horizontal, generally planar mold having a plurality of receptacles each for receiving a respective one of a plurality of rigid facing elements so as to arrange the facing elements with front faces thereof in a common horizontal plane in a pattern defining spaces between side edges of at least some of the facing elements and side edges of adjacent ones of the facing elements;
• placing a facing element in each of the receptacles;
• applying into the mold a layer of a cementitious material so as to fill in at least the spaces between the facing elements and thinly cover the rear face of the facing elements, the cementitious material having setting characteristics so as to set to a rigid condition to form a substantially rigid surface exposed in the mold;
• placing support strips into the mold before the cementitious layer sets to its rigid condition, the support strips engaging the cementitious material and some of the facing elements;
• applying a support panel over the mold so as to leave a space between the exposed surface of the cementitious layer and the support panel;
• and
• after setting of the cementitious layer, injecting a cellular polymeric material into the space between the exposed surface of the cementitious layer and the support panel to form a foamed rigid sheet of the polymeric material filling the space, the sheet bonding to the exposed surface of the cementitious layer substantially without penetration into the cementitious layer, the sheet also engaging the support strips and the support panel;
• and mounting and bonding a support panel to the rear surface of the sheet.