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 wall panel includes an outer surface layer, an oriented strand board layer, and mounting channels. The outer surface layer includes an outer surface, an inner surface, and edges. The oriented strand board layer includes an outer surface, an inner surface, and edges, with the outer surface of the oriented strand board layer being attached to the inner surface of the outer surface layer. The mounting channels are defined along and between the edges of the outer surface layer and the oriented strand board layer, and define a region recessed from the edges of the outer surface layer and the oriented strand board layer.

Abstract: Elementary module (21) for forming a thermal bridge break (1) between a wall (2) and a concrete slab (3).

Abstract: A modular wall panel for manufacturing an exterior wall is made from a substantially flat rectangular insulating foam core having two opposite surfaces, two opposite side edges, a width defined by the opposite side edges, opposite top and bottom edges, and a length defined by the top and bottom edges. The panel also has at least one elongated longitudinal support stud and at least one elongated transverse stud, each mounted to the foam core. The first side edge of the panel has a first face extending between the opposite surfaces and the second side edge has a second face extending between the opposite surfaces. Each face defines an elongated first channel when the first face of one panel is abutted against the second face of an adjacent panel and the first channel has an elongated first cavity and an opening extending to the first surface of the panels.

Abstract: An uncured, thermoset resin sheet is reinforced with oriented fibers and is slit to define a desired length for the fibers. A series of the sheets are cut and stacked to form integrated layers of the composite material for a structural panel. The panel has two outer layers that sandwich two shorter layers on each end, and syntactic or foamed resin layer in between. Each of the composite layers is formed from the same materials and by the same process, but may vary in the directional orientation of their fibers. The uncured panel is assembled into a flexible, substantially flat configuration is heated and formed to the contours of a tool having a undulated surface geometry. The panel is further heated to cure the combined composite and syntactic resins into a series of undulations that permeate each of its layers. In one embodiment, the undulations are in a smooth, sine wave-like pattern that allow the panel to maintain a planar configuration.

Abstract: An insulative building wall structure including parallel channel-bearing track and load plate structures with a plurality of spaced apart posts extending perpendicularly there between and a plurality of respective foam panels disposed between the posts. The panels are provided with a plurality of vertical slits such that width adjustment thereof can be accomplished on-site by removing an appropriate number of slitted strips from a panel. Each panel is maintained such that a void is formed between respective interior edges of the channels and the interior surfaces of the foam panels. A wall surface panel is secured to respective interior outer edges of the track and load plate structures to create an insulative dead air space, corresponding to the above-described void, between the interior surface of each foam panel and the wall surface panel.

Abstract: A generally planar, structural insulated panel for building construction includes a pair of outer facings disposed on opposed surfaces of a plastic foam core. One of the outer facings is of a gypsum or cementous composite for use on the panel's inner surface, while the other outer facing is of oriented strand board (OSB) or other conventional building material which forms the panel's outer surface. Disposed between and laminated to the inner surface of the gypsum or cementous composite facing and the plastic foam core by a conventional bonding agent is a sheet of paper impregnated with urethane or polyisocyanurate plastic. The impregnated sheet of paper serves as a vapor barrier near the panel's inner surface to prevent moisture from permeating from the warm interior of the structure through the plastic foam insulation to the outside.

Abstract: A cast-concrete simulated log has a longitudinal axis and an outside surface simulating a natural log appearance, and also has at least one triangular rebar reinforcement embedded in the concrete in a plane at substantially a right angle to the longitudinal axis, with corners of the triangular rebar exposed at the outside surface, such that the exposed corners of the rebar triangle are available as connection points for attachment to other structures or for lifting and manipulating the log. In some cases there are two or more embedded rebar triangles spaced along the length of the log, and the concrete is colored to simulate the color of a natural log. Concrete logs are assembled to simulate large-woody-debris.

Abstract: A generally planar structural insulated panel for use in the wall of a building structure includes an inner core of insulating material such as plastic foam. Disposed on and attached to opposed surfaces of the insulating core are outer facings in the form of thick sheets of paper impregnated with plastic such as urethane, polystyrene or polyisocyanurate. The plastic impregnated paper (PIP) sheets are 0.14″ to 0.70″ thick and extend several inches beyond the edges of the panel's insulating core. The PIP sheets provide the panel with high tensile strength and the peripheral edges of the PIP sheets are adapted to receive coupling pins such as nails, screws or staples for mounting the panel to 2× dimensional lumber members in the building structure. The high tensile strength of the PIP sheets also provides secure mounting of the panel to the adjacent structural members.

Abstract: The present invention relates to a loading dock door seal for sealing the space between a loading dock door opening and a vehicle backing up to the opening and an elongated longitudinal pad member for use in the loading dock door seal. The elongated longitudinal pad member comprises a mounting face for mounting said pad member to a surface; a sealing face for sealingly engaging the rear edge of a vehicle which backs up to and abuts against the pad member; whereby the pad member is formed of a first compressible resilient material, having a first predetermined degree of flexibility and having at least one flexing zone therein, the at least one flexing zone permitting the forced movement of the sealing face relative to the mounting face and thus the surface, to accommodate the movement of a vehicle in abutting and sealing engagement with the pad member.

Abstract: Provided herein are blocks useful in the construction of walls and other structures. The blocks include in their design features which render them to be interlocking, and which provide for a wall constructed from the blocks to include a plurality of horizontal and vertical channels that are adapted to receive reinforcing rods (“rebar”). Once a two-dimensional network of rebar is disposed in the interior of such a wall constructed from blocks according to a preferred form of the invention, a castable concrete may be poured into the wall and caused to exist in the spaces between the rebar and the blocks of the invention. By such construction, a wall comprising concrete in its interior that is reinforced in two dimensions is provided, wherein reinforcement in the third dimension is provided by the interlocking feature of the tops and bottom portions of blocks in adjacent rows with one another.

Abstract: An improved thermoplastic door jamb comprises a blown thermoplastic core encased in a non-blown thermoplastic skin. A pair of aluminum reinforcing members are embedded in the thermoplastic core and are positioned and configured to receive fasteners for securing case molding and brick molding to the inside and outside edges of the jamb respectively. The reinforcing members stabilize the jamb and, in conjunction with the attached moldings, form a rigid stable structure.

Abstract: The present invention relates to an improved casting process of mass producing complete lightweight cementitious house walls. More specifically, the invention relates to the manner in which thin cementitious skins are separately cast on either face of the wall against a sub-assembly of thick panels of insulation material shaped and located in a manner to control the movement of displaced cementitious fluid so that the exposed top and bottom chords of small vertical structural trusses, sandwiched between these the panels of insulation and other perimeter reinforcing members are encased with the least amount of cementitious material. The size and strength of each wall component can be varied to achieve the specific characteristics of the wall. Smooth or textured faces in the casting beds reproduce whatever profiles are of required on the finished walls. Accurate window and door openings are cast in such a manner as to eliminate the need for trim.

Abstract: The invention relates to a structural member and a process for producing a structural member with at least one layer of plastic and with a layer inside the structural member of a material that has a substantially higher modulus of elasticity than plastic. The member also has at least one system plane that is part of the structural member and along which the structural member has substantially homogenous properties and a substantially homogeneous structure. The invention is characterized in that along the system plane, at least one inner layer and a respective outer layer consisting of plastic are provided between which two layers each separated from each other and traversing the system plane with the second higher modulus of elasticity are provided.

Abstract: A modular wall component with an insulative thermal break for preventing the creation of a continuous thermal path across the modular wall component. The modular wall component may be formed with an insulated frame structure that is fixed to an open frame structure with an insulative thermal break interposed therebetween. The insulated frame structure may be formed with a plurality of vertical track members coupled to an upper track member and a lower track member. At least one sheet of insulative material is interposed into the insulated frame structure. The open frame structure may have a plurality of vertical framing studs coupled to an upper framing track and a lower framing track.

Abstract: An ultra-lite modular composite building assembly system, comprising the lamination of rigid solid and expanded matrix materials, that can produce a functionally homogeneous composite structure capable of supporting over three hundred times its own weight. The rigid material, as the primary structure capable of sustained axial stress, is encapsulated within the body of the matrix material as a sheet or membrane that is bonded to and laterally braced by the matrix material. As a corrugated sheet or membrane, it may be either thermoformed or extruded and integrated into the body of the matrix composite in either a static or continuous foam molding process. The rigid material may be a solid polymer and the matrix material may be either an expanded polymer or any other structural foam matrix with similar characteristics. Further, extremities of the rigid material may be configured for tools-free interlock with adjacent building components.

Abstract: A structural insulated panel for building construction includes a planar, rigid insulating core such as of lightweight plastic foam having opposed surfaces to which are bonded respective plastic impregnated paper (PIP) sheets. Disposed symmetrically either on the inner surfaces of the PIP sheets, and thus within the panel's insulating foam core, or on the outer surfaces of the PIP sheets are spaced reinforcing strips. The reinforcing strips may be flat or formed, such as in the shape of a channel, may be of metal, gypsum composites, or wood, and are provided with an adhesive coating for bonding to the insulating foam core and a PIP sheet. The spaced metal strips increase the panel's bending strength and serve as an attachment base for internal and external finished faces, while the PIP sheets provide the panel with high tensile strength. The adhesive coating on the metal reinforcing strips further increases panel strength.

Abstract: There is provided a premanufactured structural building panel system for effectively promoting the efficient construction of the exterior wall members of a building having improved insulation, sound absorption, fire retardant and structural properties. The premanufactured structural building panels are made of a pair of C-shaped structural channels having first and second flanges. The channels are secured to a foam insulation member to form the panels. A fire retarding member can be secured to a flange of at least one of the channels to define an interior surface. The structural panels are supported on wall support members and connected to each other in a side-by-side fashion to form an exterior wall member of a building. The exterior wall members include vertical sidewalls, a horizontal roof and ceiling wall, and a pitched roof system. The interior surface of the walls can be prepared for finishing. Affixed to the exterior of the wall members is a weatherable covering.

Abstract: A New Useful Improvement. An encapsulation method for producing high quality low cost housing panels, which uses commercially fabricated pre-assembled light gage steel framed structures, with superior insulation material. The encapsulation process uses a Clamshell Jig Fixture designed specifically for this process. The pre-assembled steel housing frames are placed in the Jig Fixture and sealed. Thereafter the insulation material is injected into the steel framework via openings in the jig fixture. The insulation material is a high density Class 1 Isofoam Polyisocyanate, known as Polyurethane. It is free of Formaldehyde and CFC's or HCFCS. Its insulation “R” factor is 7.69 per inch of thickness. Finished panels result in “R” factors to 40.37, with vertical, horrizontal, wind and seismic strengths greater than building code requirements for housing. Panel attaching methods are simpler and stronger using smaller, short, light 16 to 12 gage studs, bolts, nuts and anchor plates.

Abstract: A reinforcing member for a structural component such as a rail or channel of a vehicle is provided which includes a carrier and a thermally expansible structural reinforcing material element which is fastened to the carrier by mechanical fixation or an adhesive. The mechanical fixation may be provided by a flange or other mechanical connection on the carrier or by a fastener such as a push pin extending through aligned holes and openings in the carrier and foamable material. The push pins are preferably of a synthetic resin material which more closely approximates the heat conductivity of the foamable material when the latter is activated by heat, and is sufficiently yieldable to absorb impacts to the foamable material during installation.

Abstract: An apparatus for forming precast modular units has at least two modular forms configured to be selectively arranged and interconnected in spaced-apart relation to one another, reinforcement members disposed in each of the modular forms, and connecting members each having a first end integrally connected to one of the reinforcement members and a second end extending from opposite side edges of each of the modular forms. Connectors releasably connect the second end of each of the connecting members of one of the modular forms to a corresponding connecting member of another one of the modular forms to integrally connect the modular forms to one another. A molding plate is configured to be arranged between the side edges of modular forms when the modular forms are connected to one another.

Abstract: A self-supporting construction element (1, 101) of expanded plastics, in particular for manufacturing floor elements and walls of buildings in general comprises: (1) a central body (2), substantially parallelepipedic in shape and having two opposite faces (6, 7); at least one reinforcing section bar (8,9) transversally extending across the central body (2) between the faces (6,7) thereof and embedded in the expanded plastics; a lath (16) for supporting at least one layer (17) of a suitable covering material, associated to a fin (11,12) of the reinforcing section bar (8,9) lying flush with and substantially parallel to at least one of the faces (6,7) of the construction element (1,101).

Abstract: An outer structure for a refrigerated food storage apparatus includes an outer shell forming a visible exterior of the apparatus; and an inner liner made of molded plastic and coupled to the outer shell, to form an inter-panel space to be filled with a body of foam insulation. The inner liner includes bosses of a predetermined length, integrally formed with the inner liner at regular intervals and extending toward the outer shell, to support and maintain a constant spacing between the outer shell and inner liner; a foam-injection inlet for injecting foam; and vents for exhausting air and gases generated during a foam injection process. A reactive foam completely fills the inter-panel space, to form a consistent body of insulation. The force of the reactive foam filling the inter-panel space closes a hinged first flap for covering the foam-injection inlet and a plurality of hinged second flaps for covering the vents.

Abstract: By using a thermal insulation foam/film laminate wherein each major planar surface of a foam panel has a facer film bonded thereto that meets certain performance criteria rather than a foam panel by itself, composite walls that have a foam panel sandwiched between concrete layers can be made with fewer steps.

Abstract: Building element including of two parallel welded wire grid mats (1, 2), of straight web wires (7) which hold the wire grid mats at a predetermined distance apart and are joined at each end to the two wire grid mats, and of an insulating body (8) which is arranged between the wire grid mats and through which the web wires pass, wherein at least one of the wire grid mats is in the form of a grid reinforcement mat which possesses a minimum strength of the weld nodes which complies with the static requirements applicable to the building element, corresponding mechanical strength of the grid mat wires (3, 4) and also corresponding diameters and mutual spacings of the grid mat wires, and wherein the web wires are arranged in predetermined directions relative to the wire grid mats, and the insulating body is held at a predetermined distance from each of the wire grid mats.

Abstract: A three-dimensional laminate beam is formed by inserting a preformed foam core insert within a hydra-formed metal section having curved three-dimensional geometry. A reinforcing polymer is pumped in and around the foam core insert so as to be adjacent the inside wall of the shell. The polymer bonds to the inside wall of the shell upon the polymer being cured.

Abstract: Disclosed is a panel building component, method of making same, and method of fabricating a load-bearing, insulating building wall using the panels and concrete pour after the panels are positioned on site. The panel includes at least one foam core, vertical C-studs, a channel shaped foot member in engaging relationship with the bottom edge of the foam core and the bottom end of the C-studs, two siding members, spacers to keep the foam core centered between the siding members prior to filling the panel with concrete, and the concrete itself. The foam core and C-studs are fabricated shorter than the finished height of the panel so that rebar steel reinforcing rods can be laid horizontally such that when the panel is filled with concrete, the top portion will be a concrete and rebar tie beam. The method of making same is simply assembly of the foregoing components, less the concrete.

Abstract: Precast insulated concrete wall panels are made by pouring a first concrete layer into a form. An insulation layer is then supported above the first concrete layer so as to create a space therebetween. The second concrete layer is then poured on top of the insulation layer before the first concrete layer has cured. Connectors are anchored in the first and second concrete layers so as to tie the layers together. After the first and second concrete layers have cured, the wall panels can be lifted, transported, and assembled into a wall structure. An intermediate layer of concrete can be poured into the air gap of the wall panels such that the panels define the form for the intermediate concrete layer and become an integral part of the wall structure. The wall structure may extend below or above grade and may be multi-tiered. The edges of the wall panels are contoured so as to interlockingly matingly engage when assembled into the wall structure.

Abstract: A lightweight, low cost, insulating construction panel having a rectangular channel-iron frame, an outside face of lightweight corrugated metal, a main filler comprising a perlite and pumice binder sandwiching an insulating foam core. The construction panel has a plurality of vertical channel irons spaced in succession and forming a plane common to an inside face of the panel. Two weld wire screens are disposed against each of the inner surface and the outer surface of the foam core, and fastened together through individual weld wires extending horizontally through the foam core. The outside face may have a decorative, cementitious material. Each box frame has attachment means along each of four perimeter sides capable of mechanical attachment to a foundation and to at least three other panels so as to become load-bearing. The construction panel is strong, flexible, termite and fire-proof, and hurricane and earthquake resistant.

Abstract: A modular building construction and components thereof. A foundation for a building includes anchor bolts extending around its periphery. A metal lower track is installed over the anchor bolts and secured thereto with nuts and rod couplers. Elongated connector rods are threaded onto the upper ends of the couplers. Pre-manufactured modular wall panels, integrally molded with a metal stud along a first lateral edge and a complementary recess along a second lateral edge, are successively installed in the track. A first panel is installed with an open side of the stud surrounding the connector rod. The second, adjacent panel is installed with its second lateral edge facing the stud. The two panels are slid together to surround and enclose the connector rod. The process continues until the entire peripheral wall is formed. A metal upper track is laid over the upper ends of the wall panels with the connector rods extending therethrough.

Abstract: An improved mounting for attaching an outer and inner facing material to a wall. The wall comprises a plurality of interlocking foam blocks with each of the plurality of interlocking foam blocks having an inner and an outer block surface for defining an outer and inner wall surface. Each of the plurality of interlocking foam blocks has a vertical aperture for filling with a curable material. A plurality of grooves are defined in the outer and inner block surface of the plurality of interlocking blocks. The plurality of grooves are aligned with the plurality of grooves in an adjacent layer for providing a plurality of continuous wall grooves. A plurality of outer and inner mounting strips are insertable within the plurality of outer and inner continuous wall grooves.

Abstract: A hollow reinforced structural member has a bulkhead having a layer of thermally expanded resin disposed between opposed side walls. A sleeve is retained within the resin layer and is oriented perpendicular to the longitudinal axis of the reinforce structural member. The sleeve is an alignment with bolt holes in opposite sides of the reinforced structure such that a bolt can be inserted there through. A component can then be bolted to the reinforced structural member at the site of the reinforcement. The invention not only increases the strength of the part, but also reduces vibration and noise transmission.

Abstract: A structural panel system that has two skin members that are separated by a plurality of semi-flexible support members disposed therebetween. The support members and the skin members are adhered together by a semi-flexible core member. The outer skin member is movable relative to the inner skin member. The first skin member may be perforated and encapsulated by either the core member or a cementitious material to provide a variety of panel surfaces.

Abstract: A molded construction product, having one or more walls and an inner core section, including a composition matrix having a resin system, a catalytic agent, and filler compounds for forming the walls; a foam core system for forming the inner core section, a curing agent and a drying agent. The resin system is for providing mechanical and physical characteristics of hardness and rigidity to the exterior walls of the molded product. The catalytic agent is for activating the reaction for the polymerization of the resin system. The filler compounds for reinforcing the walls. The foam core system is for producing the inner core section having three-dimensional cross-linking and a core density of 3.5 pounds per cubic foot. The curing agent is for cross-linking of polymers within the resin system for forming the exterior walls to be hard, rigid, and infusible. The drying agent is for drying and binding of excessive moisture within the composition.

Abstract: A laminated composite building component, capable of sustained axial stress as a primary support structure and enclosure of a building structure, comprising a lamination of rigid and resilient material, said rigid material formed of sheets with continuous corrugations parallel to the supporting axis and which have opposite faces being bonded to and encapsulated by said resilient material, said resilient material being a cellular foam matrix, an adhesive or fusion that bonds the rigid and resilient material together in either a static or continuous laminating process, said resilient material forming two outer surfaces spaced from the rigid material, said rigid material having opposite lateral edges being exposed from said resilient material, said lateral edges of the rigid material having return flanges for interlocking said laminated composite building component with adjacent building component, and said building components capable of being supplied and distributed in generic lengths and custom field-cut like

Abstract: An asymmetric structural insulated panel for building construction includes a generally planar insulating foam core such as of expanded polystyrene, urethane or polyisocyanurate plastic. Adhered to a first surface of the insulating foam core is an outer facing of a conventional building material such as wood, oriented strand board (OSB), gypsum composite or cement. Adhered to a second opposed surface of the insulating foam core by a conventional adhesive is a thin, high strength sheet of paper impregnated with plastic such as polyisocyanurate. The plastic impregnated paper provides a high tensile strength for the structural insulated panel to accommodate large transverse loads on the panel. Elongated “nailing” members may be affixed in a spaced manner to the inner or outer surface of the plastic impregnated paper to also provide this surface of the panel with high compressive strength and to permit the panel to withstand large axial loads.

Abstract: The present invention comprises a concrete building system with a method for fabricating composite panels using an improved design plastic connector and assembling them at the construction site to a structure which will be shotcreted on both sides to a concrete building which is highly insulated, is fire and termite proof, hurricane, earthquake and flood resistant and fulfills the requirement for flexible design. The Composite Panels are composed of two concrete layers, enclosing an insulative foam core. The skins are reinforced with wire mesh as structurally required and are connected through the foam core by structural highly insulative plastic connectors using the snap connection on both ends of the connectors so they form a tri-dimentional system and hold the wire mesh in place for the onsite shotcrete application, which includes an application of fiber for shrinkage and cracking.

Abstract: A construction form for building an insulated concrete reinforced wall includes separable and independently usable lintel block and post block sections, made from injection molding Styrofoam. The lintel block section includes a channel extending horizontally and fully along its top portion. The channel includes multiple knock-out plugs within the bottom wall. The lintel block section also has multiple parallel and vertically spaced apertures with one end opened at a lower end, and extending upward to a closed end terminating at one plug within the bottom wall of the channel. The post block section is stackable with the lintel block section.

Abstract: The present invention relates to a house building module for module systems used in house building and methods in connection herewith. According to the invention, the module includes cellular plastic and U-sections of metal fitted into the cellular plastic as well as at least one concrete reinforcement extending in the longitudinal direction of the module. A house building module according to the invention can be comprised of a wall portion with integrated foundation portion (70). For casting the concrete reinforcement a method is applied in which the module per se constitutes a casting mold.

Abstract: The present invention is directed toward a new method of building construction which eliminates traditional framed wall and trussed roof construction methods. The method of construction utilizes a polymer bonded foam-concrete structural composite building material formed from a styrene foam having a fiber reinforced, ethylene-vinyl acetate containing concrete emulsion integrally cured thereto, resulting in enhanced impact resistance and enhanced ability to withstand tensile load. The resultant structure has enhanced thermal insulation properties. The invention is further directed to a foam panel interface construction which renders the resultant structure impervious to wind damage at velocities in the range of about 155-310 mph.

Abstract: To improve sound damping in prefabricated building elements having two parallel welded wire mesh mats 1, 2, interconnected by web wires 7, 7′ enclose, therebetween, an insulating body (8) for example of foam plastic. Concrete is then sprayed on both sides over the mesh wires to form inner and outer shells. These concrete shells are interconnected by forming the insulating body with through-holes, which, upon concrete spraying, will form concrete webs or plugs (14, 14′) interconnecting the two shells, thus preventing resonant sound vibrations of the concrete shells. The through-holes (10, 11, 11′) can be molded during manufacture of the insulating body (8) or drilled or stamped therethrough, and may extend at right angles through the major extent of the foam body or obliquely, preferably downwardly and distributed randomly.