Integrated, insulated, structural building panels

Abstract

The present invention provides an integrated, insulated panel for use in the construction industry. The integrated panel includes an integrity reinforcing truss disposed between upper and lower surface panels for enhancing the overall strength of the integrated panel. An adhesive insulating material is preferably disposed between the surface panels to assist in bonding the elements of the integrated panel into one piece. The strength and integrity of an integrated panel may be varied to satisfy the needs of a particular application through varying the dimensions and materials of the structural elements.

We claim:  
     
         1 . A method of fabricating an integrated structural panel, said method comprising the steps of: 
 forming a lower panel within the form;    embedding a truss a predetermined depth in the lower panel;    inserting insulation within the truss; and    forming an upper panel within the form.    
     
     
         2 . A method as set forth in  claim 1  including the step of positioning a form on a foundation surface.  
     
     
         3 . A method as set forth in  claim 1  including the step of positioning a bond-breaking sheet on a surface of a form.  
     
     
         4 . A method as set forth in  claim 1  including the step of positioning a textured bond-breaking sheet on a surface of a form.  
     
     
         5 . A method as set forth in  claim 1  including the step of vibrating the upper and lower panel to position the wire truss at a predetermined depth.  
     
     
         6 . A method as set forth on  claim 1  including the step of introducing a fire resistance additive into the insulating material.  
     
     
         7 . A method as set forth in  claim 1  including the step of finishing the lower panel.  
     
     
         8 . A method as set forth in  claim 1  including the step of locating a frame within the mold for an opening.  
     
     
         9 . A method as set forth in  claim 1  including the step of locating a device within the mold.  
     
     
         10 . An integrated structural panel comprising: 
 an upper panel;    a lower panel, wherein said lower panel is spaced a predetermined distance from said upper panel;    a truss disposed in the space between said upper panel and said lower panel; and    an insulating material disposed within said truss, wherein said upper panel, lower panel, truss and insulating material are integral and formed as one piece.    
     
     
         11 . An integrated structural panel as set forth in  claim 8  wherein said truss is a wire cage.  
     
     
         12 . An integrated structural panel as set forth in  claim 8  wherein an upper chord of said truss is embedded in said upper panel and a lower chord of said truss is embedded in a lower panel.  
     
     
         13 . An integrated structural panel as set forth in  claim 8  including a reinforced concrete column disposed between said upper panel and said lower panel.  
     
     
         14 . An integrated panel structure as set forth in  claim 8  wherein the panels are made of a non-concrete material.