Composite Panel Systems, LLC

Custom Millworking, Inc.

Glenn P Schiffmann

Gerhard P Schiffmann

Daniel J Wojtusik

Daniel Wojtusik

David R Cox

Michael Justin Millis

Light weight fiber-reinforced polymeric structural building panels and methods; sized, configured for fabrication of non-portable wall structures permanently fixed to natural base. The panel main body, and studs, can be fabricated separately, then assembled to each other to complete panel fabrication. Methods for making the main body are hand lay-up, or pultrusion. Studs are typically pultruded, and subsequently prepared having consistent thickness, flat surface, across the width of the stud end wall which is to be mounted to the main body. Foam blocks are between inner and outer layers of the panel. Foam blocks can be prepared in block clusters before assembly to the main body. In the main body, a fibrous layer is between each pair of next adjacent foam blocks. Intercostals extend 'y' and 'z' dimensions transverse to the length of the main body. Studs can be mounted to the main body using adhesive, mechanical fasteners, or both.

Structural building panels and panel components, panel assemblies, methods of making, and methods of using

Light weight fiber-reinforced polymeric (FRP) structural building panels and panel assemblies, sized and configured for construction of non-portable wall structures permanently fixed to the ground. Fibers in the panel are typically oriented within 15 degrees of a top-to-bottom, e.g. axial, direction in the panel providing, in part, enhanced top-to-bottom crush strength of a panel/wall. The panels typically have a bias to deflect toward the surface of the panel which faces outwardly of the building, toward the backfill soil which faces the panel on the outside the building. Panels of the invention typically have mass of no more than 18 pounds per foot height per linear foot length of the building panel, and vertical crush resistance capacity of at least 2000 pounds per linear foot length of the building panel, using a safety factor of 3.

Building panel assemblies and methods of use in wall structures

Footer products, and footers made with such products. Such product includes an insulating member between its upper and lower surfaces. The upper surface receives a load. The interior transfers the load from the upper surface to the lower surface, and distributes the load laterally and longitudinally such that the load received at the lower surface is within the load-bearing capacity of underlying soil. The product provides a thermal shock barrier between underlying soil and the interior of the building. The insulating member can comprise the entirety of the product, or can be combined with top and/or bottom load distributing layers, or can be combined with intercostals which extend top-to-bottom through the foam. Such footers are useful in constructing structures which use footers to spread the overlying load onto a greater surface area of the underlying soil than the cross-section area of the structure which presents the load to the footer.

Footer, footer elements, and buildings, and methods of forming same

Light weight fiber-reinforced polymeric (FRP) structural building panels and panel assemblies, sized and configured for construction of non-portable wall structures permanently fixed to the ground, optionally tying overlying structure to an underlying footer through such panels and panel assemblies. Fiber schedule and fiber orientation in the panels provide enhanced properties of the panels. Fibers are typically oriented within 15 degrees of a top-to-bottom direction in the panel providing, in part, enhanced top-to-bottom crush strength of a panel/wall per length dimension related to mass of the panel/wall per unit length and/or limited deflection of the panel/wall. Panels of the invention also have a bias to deflect toward the surface of the panel which faces outwardly of the building, toward the backfill soil which faces the panel, outside the building.

Light weight fiber-reinforced polymeric (FRP) structural building panels and panel assemblies, sized and configured for construction of wall structures. Fiber schedule and orientation in the panels provide enhanced properties of strength of a panel/wall per unit dimension relative to FRP layer thickness and/or mass of the panel/wall per unit dimension. Panel profiles as molded having draft angles, and molds to make such profiles, enhance panel fabrication.

Building panels and methods of making

Light weight fiber-reinforced polymeric (FRP) structural building panels and panel assemblies, sized and configured for construction of wall structures permanently tied to the ground, optionally tying overlying structure to an underlying wall using such panels and panel assemblies. Fiber schedule and orientation in the panels provide enhanced properties of strength of a panel/wall per unit dimension relative to FRP layer thickness and/or mass of the panel/wall per unit dimension.

Light weight fiber-reinforced polymeric (FRP) structural building panels and panel assemblies, sized and configured for construction of wall structures. Fiber schedule, layer securement, and orientation in the panels provide enhanced properties of strength of a panel/wall per unit dimension relative to FRP layer thickness and/or mass of the panel/wall per unit dimension.

Building panels

Wall panels and building walls, comprising inner and outer layers, and spaced reinforcing webs extending between the inner and outer layers. Optionally studs extend inwardly from the inner layer away from the outer layer with one of the stud legs on each stud being aligned with one of the reinforcing webs, or the building load delivered to an underlying footer varies less than 50% per 10 foot length of the wall, or height of the wall varies no more than 0.25 inch over a 40 foot length of the wall. The resulting wall panel can provide tough, water-proof, otherwise weather-proof, building systems and buildings.

Method of fabricating building wall panels

A tough, water-proof building system, and methods of making the system elements and constructing buildings, which provides wall, ceiling, and floor structural panels and corresponding walls, ceilings, and floors. The walls can be designed to have vertical and horizontal strengths sufficient to be used in place of concrete, as an engineered solution, both above grade and below-grade, including in severe weather conditions, such that no concrete need be used except for floor slabs. Panels have inner and outer layers, and structurally reinforcing members. Structurally-reinforcing members extend, typically as a layer and/or stud, the full height of a wall, at spaced locations along the length of the wall. Spaces between the structurally reinforcing members are optionally filled with rigid foam. An optional reinforcing stud is attached to, or overlaid by, the inner layer, and extends inwardly into the building from what is otherwise the inner surface of the building panel.

Buildings, building walls and other structures

A tough, water-proof building system provides wall, ceiling, and floor structures, as well as accessories. The walls can be designed to have vertical and horizontal strengths sufficient to be used in place of concrete, as an engineered solution, both above grade and below-grade, including in severe weather conditions. Walls have inner and outer layers, and structurally reinforcing members extending, typically as a layer and/or stud, the full height of the wall, at spaced locations along the length of the wall. The spaces between the structurally reinforcing members are optionally filled with insulating foam. An optional reinforcing stud is attached to, or overlaid by, the inner layer, and extends inwardly into the building from what is otherwise the inner surface of the building panel/wall panel. A building floor can be supported from the load-bearing wall, at locations on the floor support members which are below the top of the load-bearing wall.

A method of constructing a building or building appurtenance, optionally without structural use of concrete except for floor slabs. The method contemplates excavating a hole to establish a natural base on which the structure is to be constructed, establishing layout locations where upright walls or other supports of the structure are to be erected, establishing a fabricated footer, optionally a fiber-reinforced polymeric footer, along the laid-out locations of the supports, placing pre-fabricated load-bearing fiber-reinforced polymeric building panels or other supports on the fabricated footer, and connecting the pre-fabricated wall panels or other supports to each other according to the structure plan thereby developing load-bearing walls or other supports, and erecting overlying structure on the load-bearing walls or other supports.

Methods of constructing buildings and building appurtenances

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.

A tough, water-proof building panel, made of fiber-reinforced polymer, is useful in making structural walls, ceilings, and floors of buildings. Upstanding such walls can have vertical and horizontal strengths sufficient to be used in place of concrete, as an engineered solution, both above grade and below-grade, including in severe weather conditions. Panels effectively have inner and outer layers, and structurally reinforcing members. Structurally-reinforcing members extend, typically as layer and/or stud, the full height of the wall panel, at spaced locations along the length of the panel. Spaces between the structurally reinforcing members are optionally filled with rigid thermally insulating foam. Optional reinforcing studs are attached to, or overlaid by, the inner layer, and extend inwardly into the building from what is otherwise the inner surface of the building panel. Panels can be made by e.g. assembling pre-fabricated blocks and/or webs, by evacuating a mold, and by pultrusion.

A tough, water-proof building system which provides walls and wall sections for use on upright walls, ceilings, and floors, and appurtenances, as well as accessories which make such structures more versatile. The walls and wall sections can be designed to have vertical and horizontal strengths sufficient to be used in place of concrete, as an engineered solution, both above grade and below-grade, including in severe weather conditions. A wall section has inner and outer layers, and structurally reinforcing members which extend, typically as a layer and/or stud, the full height of the wall section, at spaced locations along the length of the wall section. The spaces between the structurally reinforcing members are optionally filled with rigid foam. An optional reinforcing stud is attached to, or overlaid by, the inner layer, and extends inwardly into the building from what is otherwise the inner surface of the wall or wall section.

Walls and wall sections

A method of making tough, water-proof building panels depositing a first fiber-rich layer onto a support, the first fiber-rich layer having a width defined by first and second side edges, a length direction, and a top surface; placing foam blocks on the first layer, lengths of the foam blocks extending generally between the first and second side edges of the first fiber-rich layer; depositing a second fiber-rich layer onto the combination of the first fiber-rich layer and the foam blocks, thereby to develop an uncured precursor to the building panel; and curing the uncured precursor to the building panel thereby to make a generally rigid structural building panel.

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St. Germain, WI, United States of America

Glenn P Schiffmann