US 8,272,190 B2Granted

Method of fabricating building wall panels

AssigneeComposite Panel Systems, LLC

InventorsGerhard P. Schiffmann, Glenn P. Schiffmann

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Abstract

Methods of fabricating wall panels by generally continuously pultruding a wall panel profile comprising inner and outer layers, and spaced reinforcing webs and/or foam extending between the inner and outer layers, optionally studs extending inwardly from the inner layer, away from the outer layer. The so-continuously pultruded wall panel optionally has male and a female edges. The wall panel is periodically cut for wall panel height, thereby creating an ongoing stream of cut wall panels. The panels are advanced through a corner index station, and indexed at right angles while maintaining orientation of the panels. The wall panels leave the indexing station edge-to-edge. Resin is applied to facing edges of adjacent wall panels. Adjacent wall panels are joined to each other at the facing edges, to make a generally continuous wall panel. The so-joined wall panel is cut to desired lengths. The resulting wall panel can provide tough, water-proof, otherwise weather-proof, building systems and buildings, without structural use of concrete except in floor slabs.

Claims16

Dependent claims

A fiber-reinforced polymeric building panel, said building panel having a height extending between a top and a bottom of said building panel, a length, and a thickness, all defined when said building panel is in an upright orientation, said building panel comprising:

(a) a first outer fiber-reinforced polymeric layer defining a first outermost surface of said building panel;
(b) a second inner fiber-reinforced polymeric layer defining a second outermost surface of said building panel and being spaced from said first layer by a first distance;
(c) one or more reinforcing webs, spaced from each other, and extending from said first layer to said second layer, each said reinforcing web having a web length defined along the height of said building panel, and a web width defined along the thickness of said building panel, a given said reinforcing web lying in a first imaginary plane;
and
(d) a plurality of fiber-reinforced polymeric studs spaced from each other along the length of said building panel and extending along the height of said building panel, each said stud comprising first and second legs (128) extending away from the second outermost surface,
a said one of said stud legs (128) having a width defined along the thickness of said building panel and a length aligned with the height of said building panel, said one stud leg lying in a second
imaginary plane coincident with the first imaginary plane.

4 more elements

A fiber-reinforced polymeric building panel, said building panel having a height extending between a top and a bottom of said building panel, a length, and a thickness, said building panel comprising:

(a) a first outer fiber-reinforced polymeric layer defining a first outermost surface of said building panel, and comprising at least a first layer of fiberglass, in combination with a resin composition;
(b) a second inner fiber-reinforced polymeric layer spaced from said first layer, said inner layer defining a second outermost surface of said building panel and comprising at least a second layer of fiberglass in combination with the resin;
(c) a plurality of reinforcing webs, spaced from each other, and extending from said first fiber-reinforced polymeric layer to said second fiber-reinforced polymeric layer,
a building panel body being defined between said inner layer and said outer layer, including said reinforcing webs, and excluding said inner layer and said outer layer;
and
(d) a plurality of fiber-reinforced polymeric studs spaced from each other along the length of said building panel, each said stud comprising a stud core (232A), said stud core having a core outer surface facing away from said outer layer, a core inner surface facing toward said outer layer, and first and second core side surfaces extending between the core inner surface and the core outer surface, each said stud further comprising first and second stud legs (128) extending alongside the core side surfaces, and an end panel (130) extending alongside the core outer surface, said inner layer, comprising both said second layer of fiberglass and said resin, traversing alongside said building panel body from a first said stud to a second said stud, then departing said building panel body and extending about said second stud as at least a part of said first stud leg, as at least a part of said stud end panel, and as at least a part of said second stud leg, such that said second layer of fiberglass extends about only three sides of said stud core.

3 more elements

Dependencies are inferred from the claim text.

Facts

Application: 12/317,164Filed 18 Dec 2008 · continuation in part
Priority: 4 Dec 2006
Published: US 2009/0165411 A12 Jul 2009
Granted: 25 Sep 2012
Term ends: Not estimatedThe source records don’t support an estimate.

Classification26 codes

E04C 2/243
Laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20: one at least of the material being insulating
B29C 44/1285
Incorporating or moulding on preformed parts, e.g. inserts or reinforcements: the preformed part being foamed
B29C 70/52
For producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]: pultrusion, i.e.…
B29C 70/865
Incorporated in coherent impregnated reinforcing layers, e.g. by winding: completely encapsulated

Family

Application60/872,929Us provisional application · filed 4 Dec 2006
Application60/876,403Us provisional application · filed 21 Dec 2006
Application60/923,822Us provisional application · filed 16 Apr 2007
Application11/901,174Parent of this continuation-in-part · filed 13 Sep 2007
Application11/901,057Parent of this continuation-in-part · filed 13 Sep 2007
Application11/900,987Parent of this continuation-in-part · filed 13 Sep 2007
Application11/900,998Parent of this continuation-in-part · filed 13 Sep 2007
Application11/901,059Parent of this continuation-in-part · filed 13 Sep 2007
Application11/901,173Parent of this continuation-in-part · filed 13 Sep 2007
Application11/901,175Parent of this continuation-in-part · filed 13 Sep 2007
Application61/008,379Us provisional application · filed 19 Dec 2007
US 2009/0165411 A1Pre-grant publication · published 2 Jul 2009
US 7,926,241 B2Parent of this continuation-in-part
US 8,082,711 B2Parent of this continuation-in-part
US 7,926,233 B2Parent of this continuation-in-part
US 7,930,861 B2Parent of this continuation-in-part
US 7,905,067 B2Parent of this continuation-in-part
US 8,012,301 B2Parent of this continuation-in-part
US 2008/0127584 A1Published application
US 2008/0127600 A1Published application
US 2008/0127601 A1Published application
US 2008/0127602 A1Published application
US 2008/0127604 A1Published application
US 2008/0127607 A1Published application
US 2008/0148659 A1Published application
US 8,322,097 B2Related patent
US 8,272,190 B2This patent

From the US filing history. Foreign family members aren’t listed.

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