# US 8,793,966 B2 · Building panels and methods of making

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- Number: US 8,793,966 B2
- Document ID: US8793966B2
- Status: Granted
- Kind: B2
- Application number: 13/317,143
- Filed: 2011-10-11
- Published: 2012-04-12
- Granted: 2014-08-05
- Earliest claimed: 2010-10-08
- Assignees: Composite Panel Systems, LLC
- Applicants: Gerhard P. Schiffmann; Glenn P. Schiffmann; Daniel J. Wojtusik
- Inventors: Gerhard P. Schiffmann; Glenn P. Schiffmann; Daniel J. Wojtusik
- Web page: https://patentgrep.com/patent/US8793966B2

## CPC

- B29C 33/44: with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C 33/10: with incorporated venting means
- E02D 27/01: Flat foundations
- E04B 1/0007: {Base structures; Cellars}
- E04B 5/026: {with beams or slabs of plastic}
- E04C 2/243: {one at least of the material being insulating}
- E04C 2/246: {combinations of materials fully covered by E04C2/16 and E04C2/20}
- E04C 2/296: composed of insulating material and non-metallic or unspecified sheet-material (E04C2/288 takes precedence)
- E04C 2/3405: {spaced apart by profiled spacer sheets}
- E04C 2/388: {with a frame of other materials, e.g. fibres, plastics}
- E04C 3/29: built-up from parts of different material, {i.e. composite structures}
- E04C 2002/3455: {with trapezoidal corrugations}
- E04C 2002/3461: {with rectangular corrugations}
- Y10T 428/24994: Fiber embedded in or on the surface of a polymeric matrix
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- E02D: FOUNDATIONS; EXCAVATIONS; EMBANKMENTS (specially adapted for hydraulic engineering E02B); UNDERGROUND OR UNDERWATER STRUCTURES {(tunnels, tunnelling, mining E21)}
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Light weight fiber-reinforced polymeric (FRP) structural building panels and panel assemblies, sized and configured for construction of wall structures. Fiber schedule and orientation in the panels provide enhanced properties of strength of a panel/wall per unit dimension relative to FRP layer thickness and/or mass of the panel/wall per unit dimension. Panel profiles as molded having draft angles, and molds to make such profiles, enhance panel fabrication.

## Claims

### Claim 1

A fiber-reinforced polymeric budding panel, said building panel having a top and a bottom, defined when said budding panel is in an upright orientation, said building panel further having a height between the top and the bottom, a length, and a thickness, said building panel comprising:
(a) an outer fiber-reinforced polymeric layer, said outer layer defining a first outermost surface of said building panel:
(b) an inner fiber-reinforced polymeric layer, said inner layer generally defining a second outermost surface (25) of said building panel;
(c) thermal insulation in a space between said inner layer and said outer layer; and
(d) a plurality of studs extending from said second outermost layer, away from said first outermost layer, to stud end panels at distal ends of said studs,
one of the top and the bottom of said building panel defining a draft angle of 0.25 degree to 25 degrees extending, from the inner layer, across a said stud to at least proximate the distal end panel of said stud, the draft angle being based on a base line perpendicular to said outer layer.

### Claim 2 (depends on 1)

A fiber-reinforced polymeric building panel as in claim 1 wherein said draft angle is initiated at the outer layer, extends to the inner layer, and extends from the inner layer and across the respective stud to the end panel of said stud.

### Claim 3 (depends on 2)

A fiber-reinforced polymeric building panel as in claim 2, the draft angle comprising a first draft angle extending across the studs and a second draft angle extending between the inner and outer layers, the first draft angle being greater than second draft angle, both of the first and second draft angles being based on a base line perpendicular to said outer layer.

### Claim 4 (depends on 1)

A fiber-reinforced polymeric building panel as in claim 1, said building panel comprising a molded unit, fabricated in a mold, the other of said top and said bottom, as molded, defining a perpendicular angle, between the other of said top and said bottom, and said outer layer.

### Claim 5 (depends on 3)

A fiber-reinforced polymeric building panel as in claim 3, magnitude of the first draft angle being 1 degree to 25 degrees and magnitude of the second draft angle being 0.25 degree to 15 degrees.

### Claim 6 (depends on 1)

A fiber-reinforced polymeric building panel as in claim 1, magnitude of the draft angle being 2 degrees to 3 degrees.

### Claim 7 (depends on 3)

A fiber-reinforced polymeric building panel as in claim 3, magnitude of the first draft angle being 2 degrees to 3 degrees and magnitude of the second draft angle being 0.25 degree to 0.5 degree.