Composite pre-formed construction articles
First Claim
1. A composite wall panel comprising:
- a central body, substantially parallelepipedic in shape, comprised of an expanded polymer matrix, having opposite faces, a top surface, an opposing bottom surface, a male end and a female end; and
two or more reinforcing embedded members transversely extending across the central body between said opposite faces, having a central portion embedded in the expanded polymer matrix, a first exposed end extending from the central portion and the top surface, and a second exposed end extending from the central portion and the bottom surface,wherein the reinforcing embedded members include one or more expansion holes located in the central portion of the embedded members and one or more utility holes located in the first exposed end and the second exposed end;
a first concrete layer placed over the top surface encasing the first exposed end of the reinforcing embedded members; and
a second concrete layer placed over the bottom surface encasing the second exposed end of the reinforcing embedded members;
wherein the central body comprises a polymer matrix that expands through the expansion holes;
wherein the set and hardened concrete of the first concrete layer fuses through the utility holes in the first exposed end;
wherein the set and hardened concrete of the second concrete layer fuses through the utility holes in the second exposed end; and
wherein the reinforcing embedded members comprise an epoxy resin reinforced with one or more fibers selected from the group consisting of carbon fibers, aramid fibers, glass fibers, metal fibers, and combinations thereof.
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Accused Products
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.
188 Citations
18 Claims
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1. A composite wall panel comprising:
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a central body, substantially parallelepipedic in shape, comprised of an expanded polymer matrix, having opposite faces, a top surface, an opposing bottom surface, a male end and a female end; and two or more reinforcing embedded members transversely extending across the central body between said opposite faces, having a central portion embedded in the expanded polymer matrix, a first exposed end extending from the central portion and the top surface, and a second exposed end extending from the central portion and the bottom surface, wherein the reinforcing embedded members include one or more expansion holes located in the central portion of the embedded members and one or more utility holes located in the first exposed end and the second exposed end; a first concrete layer placed over the top surface encasing the first exposed end of the reinforcing embedded members; and a second concrete layer placed over the bottom surface encasing the second exposed end of the reinforcing embedded members; wherein the central body comprises a polymer matrix that expands through the expansion holes; wherein the set and hardened concrete of the first concrete layer fuses through the utility holes in the first exposed end; wherein the set and hardened concrete of the second concrete layer fuses through the utility holes in the second exposed end; and wherein the reinforcing embedded members comprise an epoxy resin reinforced with one or more fibers selected from the group consisting of carbon fibers, aramid fibers, glass fibers, metal fibers, and combinations thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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Specification