Abstract: A composite wall structure is disclosed and includes a plurality of vertically stacked building blocks forming a wall structure without mortar or other binder between contiguous blocks. Distinct, continuous layers of rigid urethane polymer foam cover both exterior sides of the wall, these foam layers being adhesively secured to the sides of the wall and extending into the surface pores of the blocks and into the vertical and horizontal seams formed by the blocks. The resultant composite wall structure can be characterized as being hermetically sealed, monolithic, insulated and having improved lateral strength imparted thereto by the exterior foam layers.

Abstract: A composite building module and method for making same including forming a bottom layer of fiber reinforced wet cementitious material, placing at least two rigid foam cores side by side on the bottom layer with the adjoining edges configured to define a channel around adjoining cores and encapsulating the cores in a fiber reinforced wet cementitious shell by depositing fibers on cementitious material around the sides of the cores and on the top thereof, wherein each channel is filled in to form a rib around the interior of the cementitious shell.

Abstract: A composite module having a rigid foam core encapsulated in a shell of reinforced cementitious material. The shell is reinforced with at least two types of material, the first being a fiber reinforcing material distributed in an interconnected random matrix substantially throughout the shell and the second being a scrim reinforcing material adjacent at least one surface of the shell and/or the rigid foam core.

Abstract: A composite panel-like building module having a rigid foam core encapsulated in a shell and reinforced cementitious material having a facing member on one main face thereof, which may be a dry wall, and a process for making the composite module.

Abstract: A process and an apparatus for substantially uniformly distributing glass fibers onto a forming bed. The apparatus is mounted above the bed for movement relative thereto along the length of the bed and is receptive of glass fibers for chopping same into desired lengths. A hood structure is downstream of the chopping and comprises three chambers. A first chamber defining a receiving zone in the process receives the chopped glass fibers which are dropped into the hood and a second chamber defining a dispersing zone is in communication with the first chamber and downstream thereof and disperses the glass fibers received from the first chamber to effect a random uniform matrix thereof along the width of the bed. The dispersion is carried out by a turbulence that is created within the chamber. The third chamber defining a distributing zone is disposed downstream of the second chamber and has an adjustable length elongated outlet aperture which extends across a desired width of the bed.

Abstract: A process and apparatus for making a plurality of building modules each having an insulating foam core encased in a shell of fiber reinforced cementitious material. A longitudinal casting zone is provided having continuous side rails and end-to-end base members having lengths corresponding to the lengths of the modules being formed. A continuous bottom layer of fiber reinforced cementitious material is cast over the base members and extending the length of the casting zone. The bottom layer is divided into lengths and lateral end members are inserted between the side rails in the spaces between the divided bottom layer lengths. A foam core is placed on each bottom layer length and wet fiber reinforced cementitious material is successively applied over the entire length of the casting zone so as to fill in the free spaces surrounding each core member and cover it with a layer of cementitious material thereby completely encasing each core member.

Abstract: A process and an apparatus for substantially uniformly distributing glass fibers onto a forming bed. The apparatus is mounted above the bed for movement relative thereto along the length of the bed and is receptive of glass fibers for chopping same into desired lengths. A hood structure is downstream of the chopping and comprises three chambers. A first chamber defining a receiving zone in the process receives the chopped glass fibers which are dropped into the hood and a second chamber defining a dispersing zone is in communication with the first chamber and downstream thereof and disperses the glass fibers received from the first chamber to effect a random uniform matrix thereof along the width of the bed. The dispersion is carried out by a turbulence that is created within the chamber. The third chamber defining a distributing zone is disposed downstream of the second chamber and has an adjustable length elongated outlet aperture which extends across a desired width of the bed.

Abstract: Composite building module having a rigid foam core encased in an enclosed shell made of fiber reinforced cement and an anchor device for attaching the module to a supporting structure. The anchor has an anchoring portion extending through the shell and an interlocking portion attached to the anchoring portion and extending into the foam core. The foam core is foamed within the enclosed shell filling the interior thereof and enveloping at least the interlocking portion of the anchor device.

Abstract: A composite building module and the process for making same. The module is provided with a rigid foam core encapsulated in a shell of reinforced cementitious material and at least one anchor device for attaching the module to external structure for lifting same. The anchor device has a base disposed on a given face of the core with the top of the base flush with the outer surface of the shell. Connected to the base are two positioning members that are inserted into the given face of the core and two load bearing members each extending along a face of the core contiguous with the given face.

Abstract: A composite building module such as a wall panel having a core of rigid foam such as urethane foam encased in a shell made of fiber (e.g. glass fiber) reinforced cement. The shell has a bottom half and a top half. The bottom half has a peripheral ledge and a rib extending above the level of the ledge. The top half has side walls forming a channel with the rib when the top half is in place on the bottom half. The core is foamed in the enclosed shell and fills the interior thereof including the channel.