The present invention is a polymeric panel system and method for production and use thereof, enabling the rapid construction of a building foundation wall or other structure and in particular a below-grade foundation. The polymeric foundation system includes polymeric wall panels and other components suitable for withstanding lateral and end compression loads. The walls include two parallel faces separated by a series of webs or ribs, where the webs and faces of the wall panels may be formed of a similar polymer material such as polyvinylchloride (PVC). The wall panels and/or other components may be extruded so as to enable the rapid production of sections of wall panels, where the panels may be cut to length and then affixed to adjacent panels to form a foundation wall. The method of affixing adjacent panels may include welding, gluing or other techniques and may be performed on the job site or in a pre-fabrication facility. Furthermore, the wall panels may be co-extruded with an insulating material inserted in the voids between the parallel faces so as to provide improved thermal performance of the foundation as well.

Modular structure for building panels and methods of making and using same

The present invention relates to an improved wall system where a wall form mold has a structural insulated core assembled to form a structural insulated panel (SIP) to form a concrete beam and concrete column to be poured anywhere within the wall as well as between building modules when placed together and erected vertically. The interlocking wall molds interlock within the wall as well as between panels and modules. The wall panels allow concrete columns and beams to be formed in any size and shape. The structural insulated core consists of interlocking foam spacers and support channels which can be glued or screwed together to form an independent wall or as part of a precast wall with columns and beams integrated within the wall panels. Insulated flanges within the wall forming mold separates the wall forming structure from the wall surfaces.

Building construction for forming columns and beams within a wall mold

Thin composite panels with interconnection schemes that are unitized with the panels, i.e., formed integrally and substantially simultaneously with the panels. Further contemplated is the application of an injection molding technique, such as reaction injection molding, in establishing a foam or polymeric core between laminates in thin composite panels. Additionally contemplated is the use of interchangeable laminate components in affording the capability of altering the coloring or other visual features of a reveal in a panel or panels.

Features for thin composite architectural panels

In one embodiment, a construction panel system comprises a first panel of one or more construction panels. The first construction panel comprises a core board, a first insulation layer coupled to a first side of the core board, and a second insulation layer coupled to a second side of the core board, where the core board provides a structural integrity for the first panel, the first insulation layer substantially covers the first side of the core board and the second insulation layer substantialIy covers the second side of the core board.

Construction Panel System And Method Of Manufacture Thereof

The present invention relates to an improved wall system where a wall form mold has a structural insulated core assembled to form a structural insulated panel (SIP) to form a concrete beam and concrete column to be poured anywhere within the wall as well as between building modules when placed together and erected vertically. The interlocking wall molds interlock within the wall as well as between panels and modules. The wall panels allow concrete columns and beams to be formed with an ICF in any size and shape. The structural insulated core consists of interlocking foam spacers and support channels which can be glued or screwed together to form an independent wall or as part of a precast wall with columns and beams integrated within the wall panels. Expanded and insulating flanges within the wall forming mold separates the wall forming structure from the wall surfaces.

Building construction using structural insulating core

Rigid structural members, profiles, joints, and forms added to structural sandwich panels to provide higher strength, integral joining joint, and single facing sheet manufacturing. Facing sheets ( 20 ) and ( 22 ), rigid structural members ( 24 ) and ( 26 ), latch side and pin side cam-locks ( 34 ) and ( 32 ), fabricated wire truss assembly ( 48 ), and rigid structural headers ( 28 ) and ( 30 ) and an integrated top plate ( 29 ) are positioned into containment form assembly ( 58 ) in the proper position. Facing sheets ( 20 ) and ( 22 ) are placed in position in the containment form assembly ( 58 ) forming a structural sandwich panel assembly. A foam resin core material ( 40 ) is injected into the structural sandwich panel assembly and allowed to cure. The resultant structural sandwich panel includes rigid structural members ( 24 ) and ( 26 ) and elongated recesses ( 36 ) and ( 38 ) which also form a joint for joining abutting structural sandwich panels together and cam-locks ( 32 ) and ( 34 ) used to secure adjoining panels together. Comer and angle panels have a comer rigid structural assembly ( 44 ).

Paul A. Brown

Papers

Structural sandwich panels and method of manufacture of structural sandwich panels