US2005284088A1PendingUtilityA1

Structural panel and method of fabrication

40
Individually held — no corporate assignee on recordPriority: Mar 31, 1999Filed: Apr 12, 2005Published: Dec 29, 2005
Est. expiryMar 31, 2019(expired)· nominal 20-yr term from priority
Inventors:Mark David Heath
E04B 2002/867E04B 2/845E04B 2/847E04C 2/044E04B 2002/8688
40
PatentIndex Score
0
Cited by
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References
0
Claims

Abstract

A process for manufacturing a structural panel includes determining structural loads to be placed upon the structural panel. The structural panel is manufactured from at least two generally parallel and spaced-apart thin-shell cementitious skins that are joined by a truss. The thickness of each cementitious skin is selected to meet the structural loads to be placed thereon and each skin is shaped to center reinforcement in the skin.

Claims

exact text as granted — not AI-modified
1 . A process for manufacturing a structural panel, comprising the steps of: 
 determining structural loads to be placed upon the structural panel; and    manufacturing the structural panel of at least two generally parallel and spaced-apart thin-shell cementitious skins joined by a truss.    
     
     
         2 . The method of  claim 1 , wherein the determining step includes the steps of collecting load data, and selecting physical characteristics of the panels.  
     
     
         3 . The method of  claim 1 , wherein the determining step includes the steps of determining longitudinal, shear and bending loads upon the structural panel.  
     
     
         4 . The method of  claim 1 , wherein the manufacturing step includes the step of sizing the components of the structural panel to meet the loads to be placed thereon.  
     
     
         5 . The method of  claim 4 , wherein the manufacturing step includes the step of varying the components of the structural panel.  
     
     
         6 . The method of  claim 1 , wherein the manufacturing step includes the steps of: 
 aligning a plurality of fillers with a plurality of trusses in an alternating sequence;    pressing the aligned trusses and fillers to form a panel core;    overlying commercially available wire mesh over opposing side surfaces of the panel core; and    attaching the wire mesh to the trusses by attaching commercially available metal ties to connection points of the wire mesh and trusses to hold the panel core together.    
     
     
         7 . The method of  claim 6 , including the step of providing masonry reinforcement trusses having two substantially parallel rods interconnected by a wire bent around the rods in a zigzag configuration having approximately 30° bends.  
     
     
         8 . The method of  claim 6 , wherein the fillers are comprised of solid foamed material filler, stabilized organic material fillers, wattles containing filler material, a bio-mass or cloth.  
     
     
         9 . The method of  claim 6 , including the step of combining a plurality of structural panels to form a structure.  
     
     
         10 . The method of  claim 6 , including the step of imbedding a commercially available lathing member within the structural panel.  
     
     
         11 . The method of  claim 6 , including the step of applying a durable coating to the panel core and attached wire mesh.  
     
     
         12 . The method of  claim 11 , wherein the durable coating comprises the cementitious skins.  
     
     
         13 . The method of  claim 11 , including the step of removing the fillers after applying the durable coating.  
     
     
         14 . The method of  claim 11 , wherein the applying step includes the step of varying of thickness of the durable coating.  
     
     
         15 . The method of  claim 11 , wherein the durable coating on one side of the structural panel is thicker than the durable coating on an opposite side thereof.  
     
     
         16 . The method of  claim 6 , wherein bailing wire is tied to the connection points of the wire mesh and trusses to hold the panel core together.  
     
     
         17 . The method of  claim 6 , wherein upholstery clamps are clamped to the connection points of the wire mesh and trusses to hold the panel core together.  
     
     
         18 . The method of  claim 1 , wherein the determining step includes the step of selecting thickness of each cementitious skin to meet the structural loads to be placed thereon.  
     
     
         19 . The method of  claim 1 , wherein the manufacturing step includes the step of shaping each cementitious skin to center reinforcement in the skin.  
     
     
         20 . A process for manufacturing a structural panel, comprising the steps of: 
 determining structural loads to be placed upon the structural panel;    manufacturing the structural panel of at least two generally parallel and spaced-apart thin-shell cementitious skins joined by a truss;    selecting thickness of each cementitious skin to meet the structural loads to be placed thereon; and    shaping each cementitious skin to center reinforcement in the skin.    
     
     
         21 . The method of  claim 20 , wherein the determining step includes the steps of collecting load data, and selecting physical characteristics of the panels.  
     
     
         22 . The method of  claim 20 , wherein the determining step includes the steps of determining longitudinal, shear and bending loads upon the structural panel.  
     
     
         23 . The method of  claim 20 , wherein the manufacturing step includes the step of sizing the components of the structural panel to meet the loads to be placed thereon.  
     
     
         24 . The method of  claim 20 , wherein the manufacturing step includes the step of varying the components of the structural panel.  
     
     
         25 . The method of  claim 20 , wherein the manufacturing step includes the steps of: 
 aligning a plurality of fillers with a plurality of trusses in an alternating sequence;    pressing the aligned trusses and fillers to form a panel core;    overlying commercially available wire mesh over opposing side surfaces of the panel core; and    attaching the wire mesh to the trusses by attaching commercially available metal ties to connection points of the wire mesh and trusses to hold the panel core together.    
     
     
         26 . The method of  claim 25 , including the step of providing masonry reinforcement trusses having two substantially parallel rods interconnected by a wire bent around the rods in a zigzag configuration having approximately 30° bends.  
     
     
         27 . The method of  claim 25 , wherein the fillers are comprised of solid foamed material filler, stabilized organic material fillers, wattles containing filler material, a bio-mass or cloth.  
     
     
         28 . The method of  claim 25 , including the step of combining a plurality of structural panels to form a structure.  
     
     
         29 . The method of  claim 25 , including the step of imbedding a commercially available lathing member within the structural panel.  
     
     
         30 . The method of  claim 25 , including the step of applying a durable coating to the panel core and attached wire mesh.  
     
     
         31 . The method of  claim 30 , wherein the durable coating comprises the cementitious skins.  
     
     
         32 . The method of  claim 30 , including the step of removing the fillers after applying the durable coating.  
     
     
         33 . The method of  claim 30 , wherein the applying step includes the step of varying of thickness of the durable coating.  
     
     
         34 . The method of  claim 30 , wherein the durable coating on one side of the structural panel is thicker than the durable coating on an opposite side thereof.  
     
     
         35 . The method of  claim 25 , wherein bailing wire is tied to the connection points of the wire mesh and trusses to hold the panel core together.  
     
     
         36 . The method of  claim 25 , wherein upholstery clamps are clamped to the connection points of the wire mesh and trusses to hold the panel core together.  
     
     
         37 . A process for manufacturing a structural panel, comprising the steps of: 
 determining structural loads, including longitudinal, shear and bending loads, to be placed upon the structural panel;    manufacturing the structural panel of at least two generally parallel and spaced-apart thin-shell cementitious skins joined by a truss;    aligning a plurality of fillers with a plurality of trusses in an alternating sequence;    pressing the aligned trusses and fillers to form a panel core;    overlying commercially available wire mesh over opposing side surfaces of the panel core; and    attaching the wire mesh to the trusses by attaching commercially available metal ties to connection points of the wire mesh and trusses to hold the panel core together; and    selecting thickness of each cementitious skin to meet the structural loads to be placed thereon.    
     
     
         38 . The method of  claim 37 , wherein the determining step includes the steps of collecting load data, and selecting physical characteristics of the panels.  
     
     
         39 . The method of  claim 37 , wherein the manufacturing step includes the steps of sizing the components of the structural panel to meet the loads to be placed thereon, and varying the components of the structural panel.  
     
     
         40 . The method of  claim 37 , including the step of providing masonry reinforcement trusses having two substantially parallel rods interconnected by a wire bent around the rods in a zigzag configuration having approximately 30° bends.  
     
     
         41 . The method of  claim 37 , wherein the fillers are comprised of solid foamed material filler, stabilized organic material fillers, wattles containing filler material, a bio-mass or cloth.  
     
     
         42 . The method of  claim 37 , including the step of combining a plurality of structural panels to form a structure.  
     
     
         43 . The method of  claim 37 , including the step of imbedding a commercially available lathing member within the structural panel.  
     
     
         44 . The method of  claim 37 , including the step of applying the cementitious skins to the panel core and attached wire mesh.  
     
     
         45 . The method of  claim 44 , including the step of removing the fillers after applying the cementitious skins.  
     
     
         46 . The method of  claim 44 , wherein the applying step includes the step of varying of thickness of the cementitious skins.  
     
     
         47 . The method of  claim 44 , wherein the cementitious skin on one side of the structural panel is thicker than the cementitious skin on an opposite side thereof.  
     
     
         48 . The method of  claim 37 , wherein bailing wire is tied to the connection points of the wire mesh and trusses to hold the panel core together.  
     
     
         49 . The method of  claim 37 , wherein upholstery clamps are clamped to the connection points of the wire mesh and trusses to hold the panel core together.

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