Fiber-reinforced sandwich panel

Abstract

The present invention may be embodied in a sandwich panel having first and second face panels each panel having a first predetermined thickness and being formed of a fiber-reinforced cementitious material. The sandwich panel further includes support frame for supporting the first and second face panels in a spaced apart configuration. The support frame is formed of a fiber reinforced cementitious material that is continuous with the cementitious material of the first and second face panels. Blocks of rigid insulation are embedded in the sandwich panel for defining a structure of the support frame.

1 . A sandwich panel, comprising: 
 a first face panel having a first predetermined thickness and being formed of a fiber reinforced cementitious material;    the cementitious material having a composition of cement, sand, fiber, a superplasticizer, and water,    a second face panel having a second predetermined thickness and being formed of the same fiber reinforced cementitious material as the first face panel; and    a support frame for supporting the first and second face panels in a spaced apart configuration, the support frame being formed of the same fiber-reinforced cementitious material and being continuous with the cementitious material of the first and second face panels; and an insulation material embedded in the sandwich panel that defines a structure of the support frame;    
     
     
         2 . A sandwich panel as defined in  claim 1 , wherein the first predetermined thickness is between about 0.25 inches and about 2.0 inches and the second predetermined thickness is between about 0.25 inches and about 2.0 inches.  
     
     
         3 . A sandwich panel as defined in  claim 2 , wherein the sandwich panel has a height greater than 4 feet, a width greater than about 4 feet, and a thickness between about 2.5 and about 8 inches.  
     
     
         4 . A sandwich panel as defined in  claim 1 , wherein the support frame comprises an upper border beam, a lower border beam, and first and second border beams that encompass the insulation material.  
     
     
         5 . A sandwich panel as defined in  claim 4 , wherein the support frame comprises one or more ribs having a length extending between the lower border beam and the upper border beam, and being substantially parallel with the first and second end beams, and coupling the first and second face panels along the length of the ribs.  
     
     
         6 . A sandwich panel as defined in  claim 5 , wherein the sandwich panel has a thickness of between about 2.5 inches and about 8.0 inches, the beams each have a width of between about 2 inches and about 6 inches, and the ribs each have a width of between about 2 inches and about 6 inches.  
     
     
         7 . A sandwich panel as defined in  claim 4 , wherein a tensile strength and a compressive strength of each border beam can each be increased by including a reinforcing bar.  
     
     
         8 . A sandwich panel as defined in  claim 7 , wherein the panel includes a reinforcing bar.  
     
     
         9 . A sandwich panel as defined in  claim 4 , wherein the sandwich panel includes an opening formed by first and second jamb beams extending between the lower border beam and the upper border beam, and being substantially parallel with the first and second end beams, by a sill beam extending between the first and second jamb beams and being substantially parallel with the lower and upper border beams, and by a header beam extending between the first and jamb beams and being substantially parallel with the lower and upper border beams.  
     
     
         10 . A sandwich panel as defined in  claim 9 , wherein each beam is strengthened by a reinforcing bar.  
     
     
         11 . A sandwich panel as defined in  claim 1 , wherein the insulation material comprises at least one rigid block of insulation.  
     
     
         12 . A sandwich panel as defined in  claim 11 , wherein the at least one rigid block of insulation is comprised of polystyrene.  
     
     
         13 . A sandwich panel as defined in  claim 11 , wherein the at least one rigid block of insulation is comprised of polyurethane.  
     
     
         14 . A sandwich panel as defined in  claim 1  wherein the cementitious material is comprised of polyvinyl alcohol fibers.  
     
     
         15 . A sandwich panel as defined in  claim 1  wherein the cementitious material is comprised of polypropylene fibers.  
     
     
         16 . A sandwich panel as defined in  claim 1  wherein the composition of the cementitious material further includes a first color that is 4#/94# of C+F/A and a second color that is 0.5#/94# of C+F/A.  
     
     
         17 . A sandwich panel as defined in  claim 1  wherein the composition of the cementitious material further includes fly ash.  
     
     
         18 . A sandwich panel as defined in  claim 1  wherein the composition of the cementitious material further includes a waterproofing agent.  
     
     
         19 . A sandwich panel as defined in  claim 1  wherein the composition of the cementitious material further includes an acrylic polymer.  
     
     
         20 . A sandwich panel, comprising: 
 a first face panel having a first predetermined thickness and being formed of a fiber reinforced cementitious material;    the cementitious material having a composition by weight before cure of between about 19% and about 41% cement, between about 0% and about 40% fly ash, between about 25% and about 41% sand, between about 1% and about 3% fiber, between about 0% and about 4% acrylic polymer, between about 0.4% and about 0.5% superplasticizer, between about 12% and about 15% water, between about 0% and about 1% waterproofing agent, between about 0% and about 3% color that is 4#/94# of C+F/A, and between about 0% and about 3% color that is 0.5#/94# of C+F/A;    a second face panel having a second predetermined thickness and being formed of the same fiber reinforced cementitious material as the first face panel; and    a support frame for supporting the first and second face panels in a spaced apart configuration, the support frame being formed of the same fiber-reinforced cementitious material and being continuous with the cementitious material of the first and second face panels; and an insulation material embedded in the sandwich panel that defines a structure of the support frame;