Abstract: A prefabricated modular panel, comprising a framework that includes a plurality of lattices, with a lattice of the plurality of lattices comprising a first elongated member and a second elongated member that are spaced apart and juxtapose laterally parallel, forming an axial length of the lattice. Further included is a third member substantially transversally oriented at an angle along the axial length of the lattice, with the third member coupling the first elongated member with the second elongated member to form the lattice, with the plurality of lattices forming the framework. The plurality of lattices are coupled with one another in parallel by a solidified filler material forming a single piece, unitary modular panel.

Abstract: A section of the wall has a plurality of interspaced structural members mounted between an upper frame member and a lower frame member, and insulating material generally filling the space between the structural members and upper and lower frame members.

Abstract: An apparatus and method for constructing pre-insulated structural panels is disclosed that has a tongue and groove assembly arrangement. Each panel may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to provide structural integrity to the panels, and resulting wall. The panels may be covered with siding, stucco, or similar materials. A chase may be formed horizontally in the panels to provide a wiring conduit through the panel. The panel may also provide when assembled, a vertical chase formed between the mated panels along the length of the panel for wiring. Acoustical properties may be formed in the surface of the EPS portions to provided added acoustical damping measures.

Abstract: The present disclosure is directed to a concrete sandwich panel. The sandwich panel may comprise a first reinforced concrete panel; a second reinforced concrete panel; an insulating panel sandwiched between the first reinforced concrete panel and the second reinforced concrete panel; a tie comprising a generally triangle wave-shaped pattern having a period defined by peaks spaced at a regular interval and a peak-to-peak amplitude greater than the thickness of the insulating panel; wherein the insulating panel has a plurality of generally linear slots defined at the regular interval of the tie for receiving the tie such that opposing ends of the tie terminate adjacent to the insulating panel, and the plurality of generally linear slots are filled utilizing an insulating material upon insertion of the tie to reduce thermal bridging; and wherein the peaks of the tie mechanically join the first and second reinforced concrete panels to the insulating panel.

Abstract: A modular construction system is made of a plurality of panels having peripheral frame elements defining a top channel, a bottom channel and side channels. An exterior planar sheet and an interior planar sheet enclose an inner core region that is filled with an adhesive bonding material that attaches the components together.

Abstract: The elastically re-expandable sealing tape for sealing a joint includes an elastically expanding foam strip of rectangular cross-section which is held in a compressed state. This is accomplished by means of at least one releasable seam, which extends across the sealing tape and consists of at least one thread, which passes through the foam strip.

Abstract: A structural insulated roof panel with a rigid foam core is disclosed. A particular embodiment includes a rigid foam core having first and second faces, a plurality of support channels being formed on the first and second faces of the rigid foam core, each of the support channels being formed in the rigid foam core with at least one bend; and a plurality of supports being insertable into the plurality of support channels such that at least one face of each of the plurality of supports is external to the first and second faces of the rigid foam core and substantially flush with a face of the rigid foam core, each of the plurality of supports being fabricated using at least four bends to produce a support that fits within one of the plurality of support channels.

Abstract: A composite reinforced mull post is disclosed or use in an exterior building entryway assembly, engaging a door on one side and a side light window on the other side. The mull post may comprise a polymer profile portion and first and second reinforcing members. The profile portion comprises a layer of polyvinyl chloride with a hollow center. The first reinforcing member comprises an engineered material such as a wood laminate, and the second reinforcing member comprises a U-shaped steel channel that fits around one end of the first reinforcing member. The reinforcing members are received within the hollow center of the polymer profile portion and run the entire length of the mull post to provide substantial rigidity to the assembly. A polymer cap layer may be co-extruded on the outer surface of the polymer profile portion to provide the mull post with a desired finished surface appearance and/or color.

Abstract: Improved concrete form insert assemblies (20) are provided for use in the construction of thermally insulated poured concrete sandwich wall structures (22). The insert assemblies (20) include a central sheet (32) of insulative material such as synthetic resin foam, which is preferably encapsulated by a sheath (78) to enhance the structural integrity of the sheet (32). A pair of reinforcing bar assemblies (46, 48) preferably made up of welded-together horizontal and vertical bars (50, 52) are respectively positioned adjacent the side surfaces (34, 36) of the sheet (32). The bar assemblies (46, 48) are secured to sheet (32) by means of connector elements (54) extending through the sheet (32) and presenting oppositely outwardly extending, apertured segments (56, 58).

Abstract: Systems, components, and methods for attaching insulating foam panels to a wall provide additional insulation by virtue of the low thermal conductivity of the foam material of which the panels are made. Structural elements disposed within the panels provide attachment features used for fixing the panels to the wall, and also provide a structural mounting for finishing materials that may be placed on the wall. A clip attaches to the attachment features and is then affixed to the wall. One or more shims may be attached to the clip for accommodating irregularities in the wall. The shims also may be used in a variety of additional applications where accommodation for irregularities in spacing is desired.

Abstract: An insulated siding panel comprises a foam insulation layer, an attachment member, and optionally a veneer layer. The foam insulation layer comprises a front face, a rear face, a tongue along a first end edge, a groove along a second end edge, and a slot defined in the rear face. The attachment member comprises an attachment rail and a member extending transversely from the attachment rail. The member of the attachment member is inserted into the slot of the foam insulation layer. When present, the veneer layer is attached to the front face of the foam insulation layer. When joined with other insulated siding panels, the interlocking occurs along the foam insulation layers to form an unbroken layer of insulation.

Abstract: A structural element (10). The inventive structural element (10) includes a frame (12) comprised of a plurality of studs (40) arranged in two rows, a first row (40A) disposed along a first side of the frame (12) and a second row (40B) disposed along a second side of the frame (12), and a foam core (18) disposed within the frame (12) between the first and second rows of studs (40). In an preferred embodiment, the studs (40) each include an exterior face (52), at least one interior face (54), at least one hollow interior cell (70), and at least one opening (74) through an interior face (54) adapted to provide access to a cell (70), and the foam (18) is adapted to fill the interior of the frame (12), penetrating within the hollow cells (70) of the studs (40) through the interior face openings (74).

Abstract: A thermal barrier includes a thermal insulating block, a layer of ultra-high performance fibered concrete integrated with the block, reinforcements embedded in the layer of ultra-high performance fibered concrete, the reinforcements protruding from the ultra-high performance fibered concrete on either side of the block. Embodiments of the invention further provides a building that includes the barrier, a process of manufacturing the barrier and a manufacturing process of the building.

Abstract: The present invention is directed to a prefabricated panel and panel building system for use in construction of houses. The prefabricated building panel has a foam body with one or more apertures in which to position one or more studs or noggins, one or more channels in the upper and lower end walls to locate about top and bottom track members respectively, and side end walls that are shaped to join to adjacent panels. The panel is located and attached to the track members to cover the track members and the one or more studs or noggins members are positioned and substantially enclosed in the one or more apertures to provide a structurally integral panel for a building structure.

Abstract: A building panel for residential and commercial construction uses a plurality of insulating blocks connected together by adhesive. The insulation blocks are typically made of foam. A plurality of support members are disposed on opposite sides of the insulating blocks and offset with respect to the adjacent support member. The support member are typically made of metal and can have different shapes including “T” shape, “U” shape, and “L” shape. Each support member has a head portion in contact with a surface of the insulating block and a stem portion extending into the insulating block and having a length less than a width of the insulating block so that a thermal conduction path of the support member is discontinuous across the insulating block. The panel can be used as a curtain wall panel in high-rise construction, as well as bodies for aircraft, automotive, and marine applications.

Abstract: A building panel structure is disclosed, in which composite building panels are used to form a structure. A composite building panel is disclosed which includes a core and a coating applied over the core. In some embodiments the core consists of a frame and one or more than one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes an inner scratch layer and an outer main brown layer. The inner scratch layer can be formed of at least two layers. The outer main brown layer can include a fiberglass mesh embedded into the outer main brown layer. A method of forming a building panel structure is disclosed which includes forming a core using a frame and one or more than block, applying an inner scratch layer to the core, and applying an outer main brown layer over the inner scratch layer.

Abstract: A resin panel for an automobile includes a skin layer formed on sides of a package tray along the direction of the thickness of the package tray and both surfaces of the package tray substantially orthogonal to the sides. An expanded layer is formed in an inner part of the package tray surrounded by the skin layer having voids by enlarging the volume of the cavity of a mold assembly during molding of the package tray to expand a thermoplastic resin in the cavity. Hollow ribs are formed of solid layers in the expanded layer to extend along the surfaces, each have a hollow formed inside over the entire length so that ends of the hollow rib continue out to the skin layer at the opposed sides of the panel. Openings in communication with the hollow rib are formed through the skin layer at the opposed sides, respectively.

Abstract: The invention concerns a building component that is assembled from a plastic foam material and a reinforcement netting of a spatial structure being at least partly embedded in the foam material, in which the plastic foam material is provided with a layer of sand at the side where the reinforcement netting projects from the foam material. The individual grains of the layer of sand are mutually connected to a binding agent to be applied in a liquid state, in which directly connecting to the layer of sand, the foam material is formed with the same binding agent.

Abstract: A structural insulated panel includes a rigid foam core without thermal bridging. A particular embodiment includes a rigid foam core having first and second faces, a plurality of stud channels being formed on the first and second faces of the rigid foam core, each of the stud channels being formed in the rigid foam core in an L-shape in cross-section. The particular embodiment includes a plurality of studs being insertable into the plurality of stud channels such that one face of each of the plurality of studs being external to the first and second faces of the rigid foam core and substantially flush with a face of the rigid foam core, each of the plurality of studs being fabricated using no more than four bends to produce a stud with a hat channel shape in cross-section.

Abstract: A structural insulated panel includes a rigid foam core without thermal bridging. A particular embodiment includes a rigid foam core having first and second faces, a plurality of stud channels being formed on the first and second faces of the rigid foam core, each of the stud channels being formed in the rigid foam core in an L-shape in cross-section. The particular embodiment includes a plurality of studs being insertable into the plurality of stud channels such that one face of each of the plurality of studs being external to the first and second faces of the rigid foam core and substantially flush with a face of the rigid foam core, each of the plurality of studs being fabricated using no more than four bends to produce a stud with a hat channel shape in cross-section.

Abstract: An insulated siding panel comprises a foam insulation layer, an attachment member, and optionally a veneer layer. The foam insulation layer comprises a front face, a rear face, a tongue along a first end edge, a groove along a second end edge, and a slot defined in the rear face. The attachment member comprises an attachment rail and a member extending transversely from the attachment rail. The member of the attachment member is inserted into the slot of the foam insulation layer. When present, the veneer layer is attached to the front face of the foam insulation layer. When joined with other insulated siding panels, the interlocking occurs along the foam insulation layers to form an unbroken layer of insulation.

Abstract: This invention provides a new wall arrangement in panels composed of glass wool and fire resistant thermal and acoustical insulating material, adequate for any kind of land and weather condition, to create a habitable environment that may be utilized in many applications such as houses, attendance stations, schools, first aid stations, motels and others. The objective of this invention is to present the conception of a modular wall which comprises a structure composed of a sheet of glass wool, with a wooden frame core and the upper part designed to support cabinets, exhaust fans, and other utensils, offering good mechanical resistance, and receiving in the interior of the hollow areas of the wooden frame, a layer of expanded polystyrene, with grooves to receive the ribs of rock wool. To complete its composition, the structure also has rock wool internal panels, wooden frame with the upper area, a new layer of expanded polystyrene, and completing the assembly a plate of glass wool is added.

Abstract: A building panel structure is disclosed, in which composite building panels are used to form a structure. A composite building panel is disclosed which includes a core and a coating applied over the core. In some embodiments the core consists of a frame and one or more than one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes an inner scratch layer and an outer main brown layer. The inner scratch layer can be formed of at least two layers. The outer main brown layer can include a fiberglass mesh embedded into the outer main brown layer. A method of forming a building panel structure is disclosed which includes forming a core using a frame and one or more than block, applying an inner scratch layer to the core, and applying an outer main brown layer over the inner scratch layer.

Abstract: Disclosed is a decorative panel having a composite structure bonded by an elastomeric cementitious coating. The cementitious coating bonds together a foam core and glass fiber mesh to form a highly durable and lightweight decorative panel. The panel can further include a finish coat of a substantially maintenance free pigmented coating. The panel may be attachment to the exterior surface of barriers and bridges. The lightweight construction of the panel adds little weight to the structure it adorns while matching or exceeding the wear characteristics of the attached structure.

Abstract: A composite building panel that includes a central body, substantially parallelepipedic in shape, containing an expanded polymer matrix, having opposite faces, a top surface, and a bottom surface; at least one embedded framing stud longitudinally extending across the central body between the opposite faces, having a first end embedded in the expanded polymer matrix, a second end extending away from the bottom surface of the central body, and one or more expansion holes in the embedded studs between the first end of the embedded stud and bottom surface through which the polymer matrix expands. A concrete layer can optionally cover a portion of the top surface and/or bottom surface. The building panel can be positioned perpendicular to a structural wall and/or foundation to provide a floor panel. The second end of the framing studs can be embedded in a second central body to provide an insulated concrete form.

Abstract: A reinforced framing member is comprised of a low density polymer base and a reinforcing member disposed within the base. The reinforcing member can be a metal, wood or a high density polymer. The low density polymer base that is reinforced can have a density of from about 6 to about to about 20 lbs. per cu. foot. The reinforcing member can have a density of from about 30 to about 90 lbs. per cu. foot.

Abstract: A system of making self-aligning concrete block structures. Structure is made of interlinking blocks that have insulative foam that is affixed during the molding process. The interior surface of the blocks is specifically designed to avoid the use of interior framing by providing wooden strips such that drywall can be directly affixed. The concrete block system include top blocks, inside and outside corner blocks, and the necessary forms for their construction.

Abstract: The present invention relates to a watertight sub-floor system for balcony or roof, in the form of a semi-rigid rollable plank of corrugated polymeric type installed in juxtaposition to form a waterproof flooring between boards and beams. Under-plank are unwrapped and cut at a desired length to avoid transverse junction with respect to water flow. Under-planks overlap parallel to water flow without loss of sealing. The corrugated under-plank has a design of crests and dips, crests widened and sloping to make possible the receiving of screws from deck board, thereby permitting the descent of water trickling from around the damaging screwing of the under-plank, and dips which bear no perforations from screwing and merely allow water to run off to protect wood structures of patios, balconies or terraces against moisture causing premature rot and to protect objects (bike, mowers . . . ) under a deck.

Abstract: A stackable insulated unit for wall construction for forming a self-supporting wall structure consists of two side wooden planks spaced apart and secured to one another with an intermediate insulating layer bonded thereto, and a plurality of stud longitudinal sections transversely extending through the insulating layer and being secured thereby. The insulating layer ensures structural integrity of the stackable unit. The stud sections are preferably spaced from at least one of the side planks. The invention also includes the method of fabrication of stackable unit.

Abstract: Multiple layers of polymer foam form structural concrete into a desired planar shape that retains a foam panel when flat or upright. The polymer foam has a planar shape and an exterior surface with multiple channels into the panel. The channels are generally wider at the bottom and narrower towards the top, preferably a trapezoidal shape. In use, the panel is placed flat within a forming frame, exterior surface upwards. Then concrete is poured upon the exterior surface and into the channels. The trapezoidal shape of the channel prevents removal of the panel from the concrete. The concrete panel can then be used flat or upright as specified for a construction project.

Abstract: Disclosed herein is a roof system including a roof deck, a previously existing roofing assembly upwardly adjacent to the roof deck, a foam material upwardly adjacent and in air sealing contact with the roofing assembly, a layer of reinforcing mesh embedded in the foam material, and a waterproof membrane upwardly adjacent of the foam material.

Abstract: A structural panel for a building structure includes first and second stud members each including a neck. Openings and venturi bridges are formed in the neck. At least one flange is attached to the neck. A foam panel extends between the studs. The openings in the neck limit the heat transferred from the stud to the edge of the foam panel. The venturi bridges in the neck also limit the transfer of heat from the neck to the edge of the foam panel.

Abstract: A method for manufacturing frame-type composite panels to a desired length comprises forming an elongate core-frame composite in which frame members have been received in slots on a slab of core material. The composite is cut to the desired length and the frame is finished by application of end members. The method described herein allows composite frame panels to be formed without restriction on the length typically due to the length of the mold in which the core is formed. A drum for use in a system for creating composite panels is disclosed having protruding rings concentric to the drum. A slab of core material is passed between two such drums which form slots in the slab for receiving frame members when they contact the slabs.

Abstract: The present invention provides a water management building wrap that may be useable between a frame structure of a building and an exterior building covering. In at least one embodiment, the building wrap comprises a permeable membrane and an extruded polymeric drainage structure secured to the second side of the membrane. In at least one embodiment, the drainage structure includes a plurality of generally vertical members having a first thickness and forming boundaries for generally vertical water drainage channels, and a plurality of generally horizontal members attached to the generally vertical members and having a second thickness less than the first thickness and forming integral joints at intersections of the generally vertical members and the generally horizontal members that provide dimensional stability to maintain the orientation of the generally vertical members and form stable vertical water drainage channels.

Abstract: A composite material and a related method of manufacturing a component. The composite material may be comprised of plastic material in an amount between about 60% and about 70% by weight, cellulosic material in an amount between about 20% and about 30% by weight, and glass material in an amount up to about 20% by weight. The composite material may be injection molded to form a component.

Abstract: Segmented dock seals for truck loading docks are described herein. An elongate, compressible pad member for use with a loading dock seal is positioned to compliantly conform to an aft end of a trailer positioned proximate to an opening in a building. The pad member includes a body portion having a front side and a back side. The body portion is composed of a compressible foam material. The pad member further includes a plurality of individual fingers projecting away from the front side of the body portion. The individual fingers are integral with the body portion and are spaced apart from each other.

Abstract: A special high durability, building device and process to construct same. This device is essentially comprised of a base or chassis, an expanded polystyrene foam, structural members (of various materials and shapes) inside the foam and a cementitious material sprayed on the exterior of the foam. The configuration is such that the walls, floor, and roof are rigidly attached to each other yet maintain good flexural strength to resist wind loads and temperature changes. The system is anticipated for mobile and manufactured homes as well as other residential and commercial use. The construction of buildings has the cementitious coating to most surfaces and the structure uses minimal or no non-durable materials such as wood, nails, and screws. This provides resistance to surface damage to walls, rot, and decay.

Abstract: A composite wall panel for exterior walls of a structure includes a polymeric foam core having a C-stud framing system embedded therein and an exterior and/or interior facing formed of a reinforced concrete bonded to the core surface and mechanically attached to the studs thereby providing increased strength, insulation and resistance to environmental conditions.

Abstract: An adjustable roof truss that includes roof truss members, roof base members and a central body containing a polymer matrix. The roof truss members include a pivot end, a connection end, a roof facing edge, an inside edge, and a pivot surface. The roof base members include a receiving end, a connecting end, a top edge, a bottom edge, and a contact surface. The roof truss members are pivotally connected to the roof base members by a pivot fastener inserted through a pivot opening on the roof base members and a stator opening on the roof truss members. One or both of the roof truss members and the roof base members include an embedded portion extending from the roof facing edge or the bottom edge respectively into the central body. Expansion hole(s) are positioned along the embedded portion such that the polymer matrix expands through the expansion holes.

Abstract: An improved structural insulated panel and panel joint includes a panel having a core with cementitious facings where the core edge is grooved and along the panel side edges rebated to accommodate a connecting column. A connecting column is “H”-shaped, formed from two “C”-shaped channels sealed together along other webs with legs directed outwardly and for use between two of the panels. Multiple wall structures and details are disclosed.

Abstract: A plank is disclosed. The plank has a cellular thermoform plastic substrate, a groove formed in at least one planar surface of the cellular thermoform plastic substrate, and a fiber reinforced thermoset plastic backing on the at least one planar surface. The fiber reinforced thermoset plastic backing includes a fiber chord positioned in the groove, a fiber matt placed upon at least a portion of the one planar surface, and a cured strip thermoset resin on the one planar surface in which the fiber chord and the fiber matt are embedded. Planks for siding of buildings and a method of forming the plank are also disclosed.

Abstract: A decorative post includes an elongated outer polymer shell having at least one longitudinal groove extending a majority of a length of the elongated shell sized and shaped to hold a decorative fence panel. The decorative fence post also includes an elongated reinforcing member disposed in the outer polymer shell, and substantially extending a length of the fence post. A foam filler is disposed inside the outer polymer shell between the shell and the reinforcement member. An aperture is disposed in the outer polymer shell near an end of the reinforcing member, and a void extends from the aperture into the foam filler adjacent to and exposing an end of the reinforcing member. The void defines a slip zone at the end of the reinforcing member into which the reinforcing member extends as the outer shell shrinks longitudinally during post mold cooling.

Abstract: Building frame shear-wall structure and associated methodology wherein the resulting structure includes (a) plural, elongate, spaced, interconnected columns and beams including elongate stretches which define and perimeter nominally open panes, and (b) within each defined and perimetered pane, an introduced, cured body of curable structural flow material spanning and effectively forming a column-and-beam-anchored rigidifying shear panel in the pane.

Abstract: A covering system for roofs and for the outside of building walls is provided in which, on top, a high range of various decorative materials and elements can be fixed without penetrating the watertight layer. The system contains protruding elements connected to the support and flexible watertight membranes arranged so as to cover and contact essentially the complete support surface, including the protruding elements. Panels, preferably rigid insulation panels with excellent resistance to water, are arranged so as to hold down the watertight membranes onto the support, thus protecting the membrane from thermal cycling, UV rays and physical damage. The panels can be fixed with non-penetrating fastening means to secure the complete system to the protruding elements and to the support.

Abstract: An architectural concrete structure and a wall system formed with a plurality of architectural concrete structure wherein each block has first and second cement sections spaced apart and joined together with steel reinforcing bars and tubular members filled with cement. The first and second sections have parallel outer wall surfaces and inner wall surfaces which taper outwardly in an upward direction. Foam insulation is secured to each of the tapering wall surfaces, which insulation members define a tapered passageway extending through the length of the structure.

Abstract: A stud panel and method of making a stud panel where interior sheathing may be a temporary piece of transparent plastic or a permanent panel of sheet rock so as to retain insulation in place and minimize scarfing. The stud panel may include studs having through holes extending in a length direction of the stud panel such that insulation in adjacent inner regions separated by such studs interlock with each other and contribute to a structural integrity of the stud panel. The stud panel may include a space between inner studs and one of the exterior and interior sheathing so as to provide a thermal and sound break between the exterior and inner sheathing so as to minimize heat, air and sound transfer between the exterior and interior sheathing.

Abstract: A prefabricated wall panel is disclosed. The panel has a first exterior facing sheet of plywood or OSB and the second interior facing sheet of plywood or OSB. Framing struts are located between the sheets to secured thereto to define a panel volume. A polymeric in-situ foam core is formed inside such panel volume. The overall panel thickness is 4 inches, plus or minus 1 quarter inch. In the finished wall assembly, thickness in combination with a sheet of drywall allows flush mounting of door jambs and window jambs, including flush mounting of trim pieces. The panel has an R value in excess of R20.

Abstract: A process for the manufacture, storage and final assembly of self-erecting structures constructed from a plurality of materials and or articles, some or all of which may be flexible and some or all may be impregnated with a curable polymer compound. The structure is folded to reduce its volume and stored in a vacuum sealed package to further reduce its volume and to prevent the impregnated curable polymer compound from curing until such time as curing is desired. When the structure is removed from the vacuum sealed packaging, it returns to its original geometry through the elastomeric memory properties of the materials used to construct the shelter. Once the shelter is removed from the vacuum sealed packaging, curing of the curable polymer compound is naturally or artificially initiated.

Abstract: A method of manufacturing a single layer building panel. The building panels include a peripheral frame having vertical and horizontal members. One or more surfaces of the building panel can be configured with a fiber reinforced layer. The building panels can be manufactured with electrical components. The building panels can also be manufactured with openings for windows, doors and the like. The interior of the panel can include a mesh material disposed therein.

Abstract: A structural insulated panel includes a structural chase or cavity to accommodate connection of the panel to an anchoring device embedded in a foundation or load bearing footing. An embodiment of the panel also includes an opening through an outer panel member providing physical and visual access to the connection within the structural chase. Another embodiment provides for an insulated structural chase also capable of accommodating an anchoring device and connecting member.