Methods of manufacturing building panels
AssigneeComposite Panel Systems, LLC
InventorsGlenn P. Schiffmann, Gerhard P. Schiffmann
Life of this patent
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Abstract
A method of making tough, water-proof building panels depositing a first fiber-rich layer onto a support, the first fiber-rich layer having a width defined by first and second side edges, a length direction, and a top surface; placing foam blocks on the first layer, lengths of the foam blocks extending generally between the first and second side edges of the first fiber-rich layer; depositing a second fiber-rich layer onto the combination of the first fiber-rich layer and the foam blocks, thereby to develop an uncured precursor to the building panel; and curing the uncured precursor to the building panel thereby to make a generally rigid structural building panel.
Claims21
A method of manufacturing a precursor to a load bearing structural building panel, comprising:
- (a) depositing a first fibrous layer onto a support, the first fibrous layer having a first side edge, a second side edge, a width defined between the first and second side edges, a length perpendicular to the width, and a top surface;
- (b) placing foam along the length of, and across the width of, the first fibrous layer thereby to develop a construct having a foam layer extending along the length of, and generally overlying the width of, the first layer, the construct having first and second sides, a construct length, and a width between the first and second sides, the foam layer defining a top surface of the construct opposite the first layer;
- (c) depositing pre-fabricated load-bearing studs on the top surface of the construct, the studs extending generally away from the first layer and away from the foam layer, with the foam layer between the studs and the first layer, and thereby defining a plurality of recesses between the studs;
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- (d) depositing a second fibrous layer onto the top surface of the construct, covering the width of the construct, including overlying and contacting each of the load-bearing studs and overlying and contacting the foam layer in the recess, thereby to develop a precursor to the building panel, having a thickness between the first and second layers, and wherein a surface of the second layer, which faces away from the foam layer, defines stud profiles and channel profiles which reflect the studs as deposited and the recesses so defined by the studs and the foam layer.
A method of manufacturing a load bearing structural building panel, comprising:
- (a) depositing a first generally continuous-length fibrous layer onto a support, the first fibrous layer having a first side edge, a second side edge, a width defined between the first and second side edges, a length perpendicular to the width, and a top surface;
- (b) placing foam along the length of, and across the width of, the first fibrous layer thereby to develop a generally continuous-length construct having a foam layer extending along the length of, and generally overlying the width of, the first layer, the construct having first and second sides corresponding generally to the first and second side edges of the first layer, and a width between the first and second sides, the foam layer having a top surface opposite the first layer;
- (c) depositing pre-fabricated load-bearing studs on the top surface of the construct, at spaced locations along the length of the construct, lengths of the load bearing studs extending generally between the first and second sides of the construct, the studs extending generally away from, the first layer;
- (d) depositing a second generally continuous fibrous layer onto the top surface of the construct, covering the width of the construct, including overlying each of the load-bearing studs, thereby to develop a generally continuous-length uncured precursor to the building panel, the precursor having a length, a width, and a top surface, whereby the second generally continuous layer defines the top, surface of the precursor;
- (e) impregnating the first and second fibrous layers with uncured curable resin before incorporating the respective layers into such construct, and incorporating the respective layers into such panel construct while the resin is still uncured;
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- (f) curing the construct thereby to make a generally rigid, generally continuous, load-bearing building panel precursor;
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- (g) separating a defined-length load-bearing building panel from the generally continuous-length precursor.
Dependencies are inferred from the claim text.