Abstract: A support beam and method for making a support beam, the support beam having a plurality of panels arranged side by side. The panels each have a core of insulative material and outer layers laminated to the core. The panels are adhered to one another and to top and bottom beam supports using bonding material.

Abstract: A columnar structural component includes a first sandwich panel bent to bound at least part of an area and a number of generally planar sandwich panels arranged to form a stack of sandwich panels. The stack of sandwich panels is at least partially in the area bounded by the first sandwich panel and the first sandwich panel and the stack of sandwich panels are cooperative with one another to form a columnar structural component.

Abstract: A support column and method for making a support column, the support column having a plurality of panels arranged side by side. The panels each have a core of insulative material and outer laminate layers laminated to the core. The panels are adhered to one another.

Abstract: A support beam and method for making a support beam, the support beam having a plurality of panels arranged side by side. The panels each have a core of insulative material and outer layers laminated to the core. The panels are adhered to one another and to top and bottom beam supports using bonding material.

Abstract: A nozzle and system for manufacturing composite sandwich panels, including an input port configured to receive a fluidic production material for forming a composite sandwich panel; a branching element coupled to the input port, wherein the production material that enters the branching element is output from a first end and a second end of the branching element; and an elongate tubular member coupled to the first end and the second end of the branching element for receiving the production material, wherein the elongate tubular member has a first end; a second end and a plurality of openings formed in the elongate tubular member such that the received production material is output through the plurality of openings. In another embodiment, the nozzle includes a second plurality of openings formed in the elongate tubular member.

Abstract: A ceiling construction and method for supporting an upper level of structure using sandwich panels having insulative cores. The ceiling construction has a lower level wall sandwich panel and an upper level wall sandwich panel, each of which with two outer layers and a core separating the outer layers and an upper level wall sandwich panel. Adhered to the lower level wall sandwich panel is a beam configured to support the upper level of the structure.

Abstract: A system and method for cleaning one or more components used to manufacture composite sandwich panels, which uses an acetone solvent and increased pressure to facilitate cleaning manufacturing equipment used to produce composite sandwich panels. The acetone solvent may be pressurized to enhance cleaning of the contaminated manufacturing equipment. A trough may be positioned to receive the acetone solvent for re-use.

Abstract: A method for forming a curved surface in a planar composite sandwich panel, the method including: providing a sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core. The first outer layer, the second outer layer and the panel core are substantially planar. The sandwich panel includes a first end, a second end and at least one edge. One or more recesses are formed in the second outer layer and the panel core of the sandwich panel, wherein each of the one or more recesses form a continuous channel between the first end and the second end along a first axis. A bonding material is applied to at least one edge of the sandwich panel. A force is applied to at least a portion of the sandwich panel to impart a curved outer surface in the sandwich panel, wherein the curved outer surface is formed by the first outer layer. The sandwich panel is then secured for a predetermined period of time to maintain the curved outer surface.

Abstract: A system and method of forming a multi-axis laminate including a production surface, a reinforcement material supply, and a resin supply, wherein the reinforcement material supply supplies a first layer of reinforcement material having a first fiber orientation to the production surface and a second layer of reinforcement material having a second fiber orientation on top of the first layer of reinforcement material, and wherein resin from the resin supply impregnates the first and the second layers of reinforcement material to form a laminate having a multi-axis fiber orientation. The reinforcement material supply may be a fiberglass material having a tri-axis fiber orientation that is layered to form a quatro-axis laminate.

Abstract: A columnar structural component and method of forming a columnar structural element from a sandwich panel includes forming a number of sets of recesses in the sandwich panel and bending the sandwich panel at each set of recesses to form a columnar structural element. The columnar structural component includes a number of support members at least partially disposed within an area bounded formed with the sandwich panel is bent in the areas of the sets of recesses.

Abstract: A roof structure may be made with one or more sandwich panels having a round corner and installed with a drainage slope (e.g., 5-10 degree) to facilitate removal of liquid (e.g., water, rain, snow, sleet, etc.) from the roof structure. The round corner may have any desired curvature and/or angle for establishing a drainage area. A bonding material may be used to secure and/or seal the underlying interface of the round corner. The roof structure may be secured to an exterior wall by the bonding material.

Abstract: A ground anchor and method for anchoring a building to the ground. The ground anchor has a base member having a core and an outer layer connected to the core. The ground anchor also has a support member having two outer layers separated from one another by a core, the support member having a top surface and a bottom surface. A bonding material connects the bottom surface of the support member to the outer surface of the base member. Bonding material also connects the top surface of the support member to a building element. The ground anchor is buried in the ground at the construction site and connected to the building to anchor the building to the ground.

Abstract: A roofing system includes a first sandwich panel, a second sandwich panel and a support panel. The first sandwich panel, which forms at least a portion of the roof structure, has a first outer layer and a second outer layer spaced from the first outer layer by a panel core. The first sandwich panel includes a first angle edge, which includes an edge portion of the panel core and an edge portion of at least the first outer layer. The second sandwich panel includes a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the edge portion of the first sandwich panel is supported, at least in part, by one or more outer surface Depending on the length of the roofing system and/or other design criteria, the roofing system includes one or more support panels secured between the first sandwich panel and the second sandwich panel to provide additional support for the roof structure.

Abstract: A number of multi-panel wall segments are connected together in a parallel orientation with bonding material to form a double wall segment. The connections between the multi-panel wall segments are bridged at a joint between the segments. In one embodiment, the connections between the multi-panel wall segments are bridged by a reinforcement member that extends on both sides of the connection between the sandwich panels of the multi-panel wall segments. In another embodiment, the joint is bridged an offset between the connections of the sandwich panels multi-panel wall segments to form a discontinuous joint. The bridged joint increases the rigidity and stiffness of the wall and also transfers loads between the multi-panel wall segments.

Abstract: A roof structure may be made with one or more sandwich panels having a round corner and installed with a drainage slope (e.g., 5-10 degree) to facilitate removal of liquid (e.g., water, rain, snow, sleet, etc.) from the roof structure. The round corner may have any desired curvature and/or angle for establishing a drainage area. A bonding material may be used to secure and/or seal the underlying interface of the round corner. The roof structure may be secured to an exterior wall by the bonding material.

Abstract: A ground anchor and method for anchoring a building to the ground. The ground anchor has a base member having a core and an outer layer connected to the core. The ground anchor also has a support member having two outer layers separated from one another by a core, the support member having a top surface and a bottom surface. A bonding material connects the bottom surface of the support member to the outer surface of the base member. Bonding material also connects the top surface of the support member to a building element. The ground anchor is buried in the ground at the construction site and connected to the building to anchor the building to the ground.

Abstract: A joint connecting a sandwich panel to a foundation comprising, a sandwich panel having a core and two outer layers separated from one another by the core, an anchor in the foundation, a U-shape member having two side walls and a bottom wall extending between the sidewalls, the bottom wall defining a opening that is aligned with the anchor in the foundation and a securing member insertable through the opening in the bottom wall of the U-shape member and engaged to the anchor to secure the U-shape member to the anchor, wherein the U-shape member is connected to the outer layers of the sandwich panel by bonding material between the outer layers of the sandwich panel and the side walls of the U-shape member.

Abstract: A roofing joint includes a union member that joins two sandwich panels. An edge portion of the sandwich panels is cut and removed, e.g., by a miter cut. The edge portion is generally cut based on the pitch of the roof for the structure. The roof joint is formed by aligning the union member between the edges of the panels. Thus, the panel cores are in contact with opposing surfaces of the union member, such that the cores of panels are in physical contact with the union member. In one embodiment, the union member extends above the surface of the roofing joint (e.g., extends above the first outer surface of the panels). In another embodiment, the union member extends below the surface of the second outer surface of the panels. A bonding material is injected or otherwise adhered to areas of intersection for the first and second panels and the union member to protect the joint from environmental elements (e.g., water penetration, snow, hail, etc.).

Abstract: An angle joint between two sandwich panels, wherein the sandwich panels each have a first outer layer and a second outer layer spaced from the first outer layer by a panel core, and an angle edge including an edge portion of the panel core and an edge portion of the first outer layer. The joint has an interface between the panel cores and the interface has an entranceway at an inner corner comprised of the edge portions of the first outer layers. A cavity in the panel cores is defined by a portion of the second outer layers and a portion of each panel core. The cavity spans across a second entranceway to the interface between panel cores. Bonding material applied in the cavity and at the inner corner connects the sandwich panels together in a manner that maintains an area of dead air space at the interface to inhibit or to reduce thermal transmissions across the joint.

Abstract: A straight joint and method for connecting two adjacent construction elements, such as sandwich panels, so as to reduce or minimize thermal bridging across the elements. The sandwich panels each have a core, an outer layer, a cavity defined by a portion of the core, and a pathway through the outer layer to the cavity. The panels are erected such that the panel cores are in contact with one another. Bonding material is injected into the cavity through the pathway to seal the joint and maintain the panels in fixed relation to one another.