초록 ▼

Methods of fabricating wall panels by generally continuously pultruding a wall panel profile comprising inner and outer layers, and spaced reinforcing webs and/or foam extending between the inner and outer layers, optionally studs extending inwardly from the inner layer, away from the outer layer. T

Methods of fabricating wall panels by generally continuously pultruding a wall panel profile comprising inner and outer layers, and spaced reinforcing webs and/or foam extending between the inner and outer layers, optionally studs extending inwardly from the inner layer, away from the outer layer. The so-continuously pultruded wall panel optionally has male and a female edges. The wall panel is periodically cut for wall panel height, thereby creating an ongoing stream of cut wall panels. The panels are advanced through a corner index station, and indexed at right angles while maintaining orientation of the panels. The wall panels leave the indexing station edge-to-edge. Resin is applied to facing edges of adjacent wall panels. Adjacent wall panels are joined to each other at the facing edges, to make a generally continuous wall panel. The so-joined wall panel is cut to desired lengths. The resulting wall panel can provide tough, water-proof, otherwise weather-proof, building systems and buildings, without structural use of concrete except in floor slabs.

대표청구항 ▼

1. A fiber-reinforced polymeric building panel, said building panel having a height extending between a top and a bottom of said building panel, a length, and a thickness, all defined when said building panel is in an upright orientation, said building panel comprising: (a) a first outer fiber-reinf

1. A fiber-reinforced polymeric building panel, said building panel having a height extending between a top and a bottom of said building panel, a length, and a thickness, all defined when said building panel is in an upright orientation, said building panel comprising: (a) a first outer fiber-reinforced polymeric layer defining a first outermost surface of said building panel;(b) a second inner fiber-reinforced polymeric layer defining a second outermost surface of said building panel and being spaced from said first layer by a first distance;(c) one or more reinforcing webs, spaced from each other, and extending from said first layer to said second layer, each said reinforcing web having a web length defined along the height of said building panel, and a web width defined along the thickness of said building panel, a given said reinforcing web lying in a first imaginary plane; and(d) a plurality of fiber-reinforced polymeric studs spaced from each other along the length of said building panel and extending along the height of said building panel, each said stud comprising first and second legs (128) extending away from the second outermost surface,a said one of said stud legs (128) having a width defined along the thickness of said building panel and a length aligned with the height of said building panel, said one stud leg lying in a secondimaginary plane coincident with the first imaginary plane. 2. A fiber-reinforced polymeric building panel as in claim 1, deflection of said building panel under rated load being limited to no more than Deflection=L/240, where L is the top-to-bottom height of said building panel, and deflection and “L” are expressed in a common unit of measure. 3. A fiber-reinforced polymeric building panel as in claim 1, said studs extending inwardly from the second outermost surface, and away from the first outermost surface, a distance greater than the first distance. 4. A fiber-reinforced polymeric building panel as in claim 1, said studs being spaced from each other by at least 16 inches, said studs extending from the second outermost surface along said first and second legs a distance of about 3.5 inches to said end panels, said stud legs and said end panels each being about 0.09 inch thick, said inner layer, said outer layer, and said reinforcing webs each being about 0.09 inch thick, said building panel, when disposed in an upright orientation and subjected to a downwardly-directed load applied at the top of said building panel, and evenly distributed between said outer layer and said end panels, having a vertical crush strength of at least 5,000 pounds per linear foot of the length of said building panel, and deflecting, between the top and bottom of the building panel, toward said outer layer. 5. A fiber-reinforced polymeric building panel, said building panel having a height extending between a top and a bottom of said building panel, a length, and a thickness, said building panel comprising: (a) a first outer fiber-reinforced polymeric layer defining a first outermost surface of said building panel, and comprising at least a first uprightly oriented layer of unidirectional fiberglass, and a surface veil, collectively in combination with a resin composition; and(b) a second inner fiber-reinforced polymeric layer spaced from said first layer by a first distance, said inner layer defining a second outermost surface of said building panel and comprising at least a second uprightly oriented layer of unidirectional fiberglass, and an intumescent veil, collectively in combination with said resin composition. 6. A building panel as in claim 5, further comprising a plurality of reinforcing webs, spaced from each other, and extending from said first fiber-reinforced polymeric layer to said second fiber-reinforced polymeric layer, said reinforcing webs comprising fiberglass arranged between said inner and outer layers, collectively in combination with said resin composition, said first and second fiber-reinforced structural polymeric layers, in combination with said reinforcing webs, defining spaces therebetween at each occurrence of the respective reinforcing webs. 7. A fiber-reinforced polymeric building panel as in claim 6, further comprising blocks of foam filling the spaces between the reinforcing webs and the inner and outer layers. 8. A fiber-reinforced polymeric building panel as in claim 7 wherein the blocks of foam are integrally connected with the combination of fiberglass layers and resin composition in the inner and outer layers. 9. A building panel as in claim 6, further comprising a plurality of reinforcing fiber-reinforced polymeric studs spaced from each other along the length of said building panel, each said stud comprising first and second legs (128) extending from the second outermost surface, away from the first outermost surface, to an end panel (130), said at least second layer of uprightly oriented unidirectional fiberglass extending about said studs at said legs and said end panels, a third layer of fiberglass being disposed inwardly in each of said studs from said second layer of uprightly oriented unidirectional fiberglass rovings, in combination with said resin composition. 10. A fiber-reinforced polymeric building panel as in claim 9, a said one of said legs (128) being aligned with one of said reinforcing webs such that a straight line parallel to the respective said stud leg can extend through both the respective said stud leg and through the respective said reinforcing web. 11. A building panel as in claim 5, further comprising a plurality of reinforcing fiber-reinforced polymeric studs spaced from each other along the length of said building panel, each said stud comprising first and second legs (128) extending from the second outermost surface, away from the first outermost surface, to an end panel (130), said at least second layer of uprightly oriented unidirectional fiberglass extending about said studs at said legs and said end panels, a third layer of fiberglass being disposed inwardly in each of said studs from said second layer of uprightly oriented unidirectional fiberglass rovings, in combination with said resin composition. 12. A fiber-reinforced polymeric building panel as in claim 11 wherein each of said first, second, and third layers of fiberglass comprises a layer of fiberglass rovings and is accompanied by an adjacent chopped strand mat layer. 13. A fiber-reinforced polymeric building panel as in claim 12 wherein the chopped strand mat layers accompanying each of the first and second layers of fiberglass rovings are between the respective rovings and the surface veil, and wherein the chopped strand mat layers accompanying the third layer of fiberglass rovings is between the respective rovings and the intumescent veil. 14. A fiber-reinforced polymeric building panel, said building panel having a height extending between a top and a bottom of said building panel, a length, and a thickness, said building panel comprising: (a) a first outer fiber-reinforced polymeric layer defining a first outermost surface of said building panel, and comprising at least a first layer of fiberglass, in combination with a resin composition;(b) a second inner fiber-reinforced polymeric layer spaced from said first layer, said inner layer defining a second outermost surface of said building panel and comprising at least a second layer of fiberglass in combination with the resin;(c) a plurality of reinforcing webs, spaced from each other, and extending from said first fiber-reinforced polymeric layer to said second fiber-reinforced polymeric layer,a building panel body being defined between said inner layer and said outer layer, including said reinforcing webs, and excluding said inner layer and said outer layer; and(d) a plurality of fiber-reinforced polymeric studs spaced from each other along the length of said building panel, each said stud comprising a stud core (232A), said stud core having a core outer surface facing away from said outer layer, a core inner surface facing toward said outer layer, and first and second core side surfaces extending between the core inner surface and the core outer surface, each said stud further comprising first and second stud legs (128) extending alongside the core side surfaces, and an end panel (130) extending alongside the core outer surface, said inner layer, comprising both said second layer of fiberglass and said resin, traversing alongside said building panel body from a first said stud to a second said stud, then departing said building panel body and extending about said second stud as at least a part of said first stud leg, as at least a part of said stud end panel, and as at least a part of said second stud leg, such that said second layer of fiberglass extends about only three sides of said stud core. 15. A fiber-reinforced polymeric building panel as in claim 14, further comprising a third layer of fiberglass extending, from a first end thereof adjacent said building panel body and a first side surface of a said stud core, alongside a said first such side surface and toward the respective core outer surface, alongside the core outer surface, and alongside the second side surface and back toward said building panel body to a second end thereof adjacent said building panel body. 16. A fiber-reinforced polymeric building panel as in claim 15 wherein said third layer of fiberglass is disposed between said stud core (232A) and said second fiberglass layer, on said stud.