Expanded foam-filled building panel
First Claim
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1. A building panel comprising:
- a frame, the frame having a front surface and a rear surface, and defining at least one cavity, the frame having at least one injection aperture, each of the at least one cavity being in fluid communication with the at least one injection aperture;
a fabric covering and bonded to the front surface and the rear surface of the frame to enclose the at least one cavity; and
an expanded foam disposed within and filling the at least one cavity, and bonded to the frame and to the fabric covering the front surface and the rear surface of the frame;
wherein the expanded foam is formed by injecting an expandable polymer through the at least one injection aperture and into the at least one cavity, which expands to fill the cavity and permeate the fabric, and to cure to form the expanded foam.
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Abstract
A manufactured building panel having a building panel frame that defines a cavity and having an injection aperture in fluid communication with the cavity, and an expanded foam disposed within and filling the cavity. A fabric covers and is bonded to a front surface and a rear surface of the frame to enclose the cavity. The expanded foam is formed by injecting an expandable polymer through the injection aperture and into the cavity, which expands to fill the cavity and permeate the fabric, and to cure to form the expanded foam that bonds to the frame and the fabric.
60 Citations
20 Claims
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1. A building panel comprising:
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a frame, the frame having a front surface and a rear surface, and defining at least one cavity, the frame having at least one injection aperture, each of the at least one cavity being in fluid communication with the at least one injection aperture; a fabric covering and bonded to the front surface and the rear surface of the frame to enclose the at least one cavity; and an expanded foam disposed within and filling the at least one cavity, and bonded to the frame and to the fabric covering the front surface and the rear surface of the frame; wherein the expanded foam is formed by injecting an expandable polymer through the at least one injection aperture and into the at least one cavity, which expands to fill the cavity and permeate the fabric, and to cure to form the expanded foam. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification