INSULATED WALL PANEL

• US 20180187420A1
• Filed: 02/28/2018
• Published: 07/05/2018
• Est. Priority Date: 09/27/2012
• Status: Abandoned Application

• Current Assignee: Ddp Specialty Electronic Materials US, LLC (DuPont de Nemours, Inc.)
• Original Assignee: Max Life, LLC
• Application Number:
  US15/907,503
• Publication Number:
  US 20180187420A1
• Time in Patent Office: Days
• CPC Class Codes: B29C 44/12 Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
• CPC Class Codes: E04C 2/04 of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibresE04C2/26 takes precedence; material or manufacture B28, C04
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04F 13/075 for insulation or surface protection, e.g. against noise or impact not used; for insulation, e.g. against noise E04B1/00
• CPC Class Codes: E04F 13/077 composed of several layers, e.g. sandwich panels E04F13/075 takes precedencenot used, see E04F13/0866
• CPC Class Codes: E04F 13/0832 without load-supporting elongated furring elements between wall and covering elements
• CPC Class Codes: E04F 13/0862 composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
• CPC Class Codes: E04F 13/0866 composed of several layers, e.g. sandwich panels or layered panels layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence
• CPC Class Codes: E04F 13/0873 the visible surface imitating natural stone, brick work, tiled surface or the like E04F13/105, E04F13/123, E04F13/147, E04F13/165, E04F13/185 take precedence
• CPC Class Codes: E04F 13/0875 having a basic insulating layer and at least one covering layer
• CPC Class Codes: E04F 13/14 stone or stone-like materials, e.g. ceramics concrete,; of glass or with an outer layer of stone or stone-like materials or glass E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00
• CPC Class Codes: E04F 13/165 with an outer layer imitating natural stone, brick work, tiled surface or the like

Abstract

The invention is an insulated wall panel system having structural elements that may be used as an exterior facade to a building. The insulated wall panel system provides a finished exterior surface, a structural component, and an insulation factor. The wall panel system may be used in new construction or in existing buildings. The wall panel system has an insulation layer, a middle cement layer, and an outer veneer layer. The outer veneer layer may include brick, stone, tile, or other material as a finished surface. The insulated wall panels may be attached directly to the studs or other structural element of a building.

Claims

1. A wall panel comprising:

a middle layer having a first and a second side; and

an inner insulation layer, comprising a two part rigid urethane pour foam having a first side chemically bonded to the second side of the middle layer;

wherein the wall panel is characterized by a lack of any additional sagging prevention layer positioned between the inner insulation layer and a fixed structural building component.

2. The wall panel of claim 1 wherein the chemical bond between the first side of the inner insulation layer and the second side of the middle layer is formed during a pour by the reaction between each one of the parts of the two part rigid urethane pour foam.

3. The wall panel of claim 1 wherein the middle layer is made from glass reinforced cement.

4. The wall panel of claim 1 wherein the middle layer is made from an extruded and pressed board.

5. The wall panel of claim 1 wherein the middle layer is poured, press-molded, extruded, vibration cast, sprayed, and/or lip formed.

6. The wall panel of claim 1 wherein in a plurality of wall panels are attached to a building structure using an attachment selected from the group consisting of:

screws, nails, bolts, welds, construction adhesive, rivets, and clasps.

7. The wall panel of claim 1 wherein one or more attachment points are positioned between the second side of the middle layer and the first side of the inner insulation layer.