# US 8,904,737 B2 · Building panel assemblies and methods of use in wall structures > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,904,737 B2 - Document ID: US8904737B2 - Status: Granted - Kind: B2 - Application number: 14/109,408 - Filed: 2013-12-17 - Published: 2014-04-17 - Granted: 2014-12-09 - Earliest claimed: 2008-12-18 - Assignees: Composite Panel Systems, LLC - Applicants: Glenn P. Schiffmann; Gerhard P. Schiffmann; Daniel J. Wojtusik - Inventors: Glenn P. Schiffmann; Gerhard P. Schiffmann; Daniel J. Wojtusik - Web page: https://patentgrep.com/patent/US8904737B2 ## CPC - E04B 1/14: the elements being composed of two or more materials (of reinforced concrete E04B1/04) - E04B 2/56: {Load-bearing} walls of framework or pillarwork; Walls incorporating load-bearing elongated members (E04B2/74, E04B2/88 take precedence; pillars E04C3/30) - B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)} - B29C 70/865: {completely encapsulated} - B29D 99/0021: {provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix} - E02D 27/013: {Shuttering specially adapted therefor} - E02D 27/02: Flat foundations without substantial excavation (E02D27/04, E02D27/08 take precedence) - E04B 1/0007: {Base structures; Cellars} - 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 2/322: {with parallel corrugations} - E04C 2/3405: {spaced apart by profiled spacer sheets} - E04C 2/38: with attached ribs, flanges, or the like, e.g. framed panels (concerned with attaching to other panels or elements to form a structure, see the places for the relevant structure, e.g. E04B2/00) - E04C 2/388: {with a frame of other materials, e.g. fibres, plastics} - B29K 2675/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof,} for preformed parts, e.g. for inserts - B29K 2715/003: Cellular or porous - B29K 2995/0015: Insulating - B29K 2995/0016: Non-flammable or resistant to heat - B29L 2031/10: Building elements, e.g. bricks, blocks, tiles, panels, posts, beams {(frameless domes B29L2025/00, doors B29L2031/724)} - E04B 2002/565: {with a brick veneer facing} - E04C 2002/3455: {with trapezoidal corrugations} - E04C 2002/3461: {with rectangular corrugations} - Y10T 428/24132: including grain, strips, or filamentary elements in different layers or components parallel - Y10T 428/24752: Laterally noncoextensive components - 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}) - 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) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - E02D: FOUNDATIONS; EXCAVATIONS; EMBANKMENTS (specially adapted for hydraulic engineering E02B); UNDERGROUND OR UNDERWATER STRUCTURES {(tunnels, tunnelling, mining E21)} - 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) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - 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 non-portable wall structures permanently fixed to the ground, optionally tying overlying structure to an underlying footer through such panels and panel assemblies. Fiber schedule and fiber orientation in the panels provide enhanced properties of the panels. Fibers are typically oriented within 15 degrees of a top-to-bottom direction in the panel providing, in part, enhanced top-to-bottom crush strength of a panel/wall per length dimension related to mass of the panel/wall per unit length and/or limited deflection of the panel/wall. Panels of the invention also have a bias to deflect toward the surface of the panel which faces outwardly of the building, toward the backfill soil which faces the panel, outside the building. ## Claims ### Claim 1 A fiber-reinforced polymeric load-bearing building panel having a length, a top and a bottom, and comprising: (a) an outer fiber-reinforced polymeric layer about 0.10 inch thick to about 0.15 inch thick, said outer layer comprising a first set of continuous fibers in a first reaction-cured resin, said outer layer defining a first outermost surface of said building panel; (b) an inner fiber-reinforced polymeric layer about 0.10 inch thick to about 0.15 inch thick, said inner layer comprising a second set of continuous fibers in a second reaction-cured resin, said inner layer defining a second outermost surface of said building panel; and (c) a plurality of load-bearing studs, spaced along the length of said building panel and extending, from said inner layer, away from the second outermost surface to end panels (130) of said studs, including away from said building panel, said studs extending along the height of said building panel, and having walls, defining outer surfaces of said studs, about 0.10 inch thick to about 0.15 inch thick, said walls of said studs comprising a third set of continuous fibers in a third reaction-cured resin, said building panel having a thickness between said inner layer and said outer layer, excluding any dimensions of said studs, of about 2 inches to about 5 inches, said building panel having a mass of no more than 8.9 pounds per foot of height per linear foot length of said building panel, and a vertical crush resistance of at least 4000 pounds per linear foot length of said building panel when a load is evenly distributed over the length and the thickness of said building panel. ### Claim 2 (depends on 1) A building panel as in claim 1, having a horizontally-directed bending resistance capacity at a locus of maximum horizontal underground loading of no more than L/180 when supported in accord with ASTM E72 and a clay load. ### Claim 3 (depends on 1) A building panel as in claim 1, having a horizontally-directed bending resistance capacity at a locus of maximum horizontal underground loading of no more than L/240 when supported in accord with ASTM E72 and a clay load. ### Claim 4 (depends on 1) A building panel as in claim 1, said building panel having a horizontally-directed bending resistance capacity at a locus of maximum horizontal underground loading of no more than L/120 when supported in accord with ASTM E72 and a clay load. ### Claim 5 (depends on 1) A building panel as in claim 1, said building panel having a vertical, top-to-bottom crush resistance capacity of at least 5000 pounds per linear foot length of said building panel. ### Claim 6 (depends on 1) A building panel as in claim 1 wherein said building panel, under a top-to-bottom load, evenly distributed between said outer layer and said end panels of said studs, deflects toward said outer layer. ### Claim 7 (depends on 1) A building panel as in claim 1 wherein said building panel, under a top-to-bottom load, evenly distributed between said outer layer and said end panels of said studs, and evenly distributed along the length of said building panel, deflects toward said outer layer, and has a horizontally-directed bending resistance capacity at a locus of maximum horizontal underground loading of no more than L/120 when supported in accord with ASTM E72 and a clay backfill load. ### Claim 8 (depends on 7) A building panel as in claim 7 wherein said budding panel has a vertical crush resistance capacity of at least 5000 pounds per linear foot length of said building panel. ### Claim 9 (depends on 1) A building panel as in claim 1 wherein at least about 60 percent by weight, of at least one of said first, second, and third sets of fibers, collectively, extends in a direction within 15 degrees of the top-to-bottom height of said building panel. ### Claim 10 (depends on 1) A building panel as in claim 1 wherein at least about 70 percent by weight, of each of said first, second, and third sets of fibers extends in a direction within 15 degrees of the top-to-bottom height of said building panel. ### Claim 11 (depends on 1) A building panel as in claim 1 wherein at least 70 percent by weight of each of said first, second, and third sets of fibers extends in a direction which is substantially aligned with, thus parallel to the top-to-bottom height of said building panel. ### Claim 12 A fiber-reinforced polymeric load-bearing building panel having a length, a top and a bottom, and comprising: (a) an outer fiber-reinforced polymeric layer about 0.10 inch thick to about 0.15 inch thick, said outer layer comprising a first set of continuous fibers in a first reaction-cured resin, said outer layer defining a first outermost surface of said building panel; (b) an inner fiber-reinforced polymeric layer about 0.10 inch thick to about 0.15 inch thick, said inner layer comprising a second set of continuous fibers in a second reaction-cured resin, said inner layer defining a second outermost surface of said building panel; and (c) a plurality of load-bearing studs, spaced along the length of said building panel and extending, from said inner layer, away from the second outermost surface to end panels (130) of said studs, including away from said building panel, said studs extending along the height of said building panel, and having walls, defining outer surfaces of said studs, about 0.10 inch thick to about 0.15 inch thick, said walls of said studs comprising a third set of continuous fibers in a third reaction-cured resin, said building panel having a thickness between said inner layer and said outer layer, excluding any dimensions of said studs, of about 2 inches to about 5 inches, said building panel having a mass of no more than 8.9 pounds per foot of height per linear foot length of said building panel, and wherein said building panel, under a top-to-bottom load which is evenly distributed between said outer layer and said end panels of said studs, deflects between the top and the bottom, toward said outer layer. ### Claim 13 (depends on 12) A building panel as in claim 12 wherein the deflection of said building panel is no more than L/120 when supported in accord with ASTM E72 and a clay load. ### Claim 14 A fiber-reinforced polymeric building panel having a length, a top and a bottom, and a height between the top and the bottom, and comprising: (a) an outer fiber-reinforced polymeric layer comprising a first set of continuous fibers in a first cured resin, said outer layer defining a first outermost surface of said building panel when said building panel is disposed in an upstanding orientation; (b) an inner fiber-reinforced polymeric layer comprising a second set of continuous fibers in a second cured resin, said inner layer being spaced from said outer layer and defining a second outermost surface (25) of said building panel when said building panel is disposed in such upright orientation; (c) a plurality of fiber-reinforced polymeric load-bearing studs comprising a third set of continuous fibers in a third cured resin, said studs being spaced along the length of said building panel and extending away from said building panel, including away from the second outermost surface; and at least about 60 percent by weight, of at least one of said first, second, and third sets of fibers, collectively, extending in a direction within 15 degrees of the top-to-bottom height of said building panel. ### Claim 15 (depends on 14) A building panel as in claim 14 wherein at least 60 percent by weight of each of said first, second, and third sets of fibers extend in a direction within 15 degrees of the top-to-bottom height of said building panel. ### Claim 16 (depends on 14) A building panel as in claim 14 wherein at least 70 percent by weight of each of said first, second, and third sets of fibers extend in a direction within 15 degrees of the top-to-bottom height of said building panel. ### Claim 17 (depends on 14) A building panel as in claim 14 wherein at least 70 percent by weight of each of said first, second, and third sets of fibers extends in a direction which is substantially aligned with, thus parallel to, the top-to-bottom height of said building panel. ### Claim 18 (depends on 14) An upright outer wall in a building comprising one or more panels as in claim 14. ### Claim 19 (depends on 14) An outer wall in a building extending at a first angle to horizontal, said outer wall comprising one or more panels as in claim 14 and wherein at least about 60 percent of the first, second, and third sets of fibers extend in directions within 15 degrees of the first angle of said building wall. ### Claim 20 (depends on 19) A building comprising an outer wall as in claim 19, as a foundation wall exposed to soil backfill loading, wherein horizontal deflection is directed outwardly toward the soil backfill and is limited to no more than L/120.