Structural panel and method of fabrication

Abstract

A method of fabricating a structural panel utilizing commercially available trusses comprising aligning a plurality of selected fillers with a plurality of selected trusses in an alternating sequence. The aligned trusses and fillers are pressed to form a panel core. Commercially available wire mesh is overlayed over opposing side surfaces of the panel core and the wire mesh is attached to the trusses by attaching commercially available metal ties to connection points of the wire mesh and trusses to hold the panel core together. The alignment of the fillers and trusses can be adjusted to accommodate different size fillers and/or trusses. Likewise, the positions of the fillers and/or trusses can be adjusted.

1 . A method of fabricating a structural panel utilizing commercially available trusses, comprising 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.    
   
   
       2 . The method of  claim 1 , 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.  
   
   
       3 . The method of  claim 1 , wherein the fillers are comprised of solid foamed material filler.  
   
   
       4 . The method of  claim 3 , wherein the solid foamed material fillers comprise solid foamed plastic.  
   
   
       5 . The method of  claim 3 , wherein the solid foamed material fillers comprise solid foamed glass.  
   
   
       6 . The method of  claim 1 , wherein the fillers are comprised of stabilized organic material fillers.  
   
   
       7 . The method of  claim 1 , including the step of imbedding a commercially available lathing member within the structural panel.  
   
   
       8 . The method of  claim 1 , including the step of applying a durable coating to the panel core and attached wire mesh.  
   
   
       9 . The method of  claim 1 , wherein bailing wire is tied to the connection points of the of the wire mesh and trusses to hold the panel core together.  
   
   
       10 . The method of  claim 1 , wherein upholstery clamps are clamped to the connection points of the of the wire mesh and trusses to hold the panel core together.  
   
   
       11 . A method of fabricating a structural panel utilizing commercially available trusses, comprising the steps of: 
 aligning a plurality of stabilized organic material 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.    
   
   
       12 . The method of  claim 11 , 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.  
   
   
       13 . The method of  claim 11 , including the step of imbedding a commercially available lathing member within the structural panel.  
   
   
       14 . The method of  claim 11 , including the step of applying a durable coating to the panel core and attached wire mesh.  
   
   
       15 . The method of  claim 11 , wherein bailing wire is tied to the connection points of the of the wire mesh and trusses to hold the panel core together.  
   
   
       16 . The method of  claim 11 , wherein upholstery clamps are clamped to the connection points of the of the wire mesh and trusses to hold the panel core together.  
   
   
       17 . A method of fabricating a number of structural panels utilizing commercially available trusses, comprising the steps of: 
 selecting a plurality of trusses;    selecting a plurality of fillers;    aligning the plurality of fillers with the plurality of trusses in an alternating sequence;    pressing the aligned trusses and fillers to form a panel core;    selecting a commercially available wire mesh;    overlying the wire mesh over opposing side surfaces of the panel core;    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    applying a durable coating to the panel core and attached wire mesh.    
   
   
       18 . The method of  claim 17 , wherein the panel core includes notches.  
   
   
       19 . The method of  claim 18 , wherein the notches are defined by angled corners of adjacent fillers.  
   
   
       20 . The method of  claim 18 , wherein the durable coating fills the notches during the applying step.  
   
   
       21 . The method of  claim 17 , wherein the aligning step includes the step of adjusting a means for aligning the plurality of fillers with the plurality of trusses.  
   
   
       22 . The method of  claim 21 , wherein the means for aligning the plurality of fillers with the plurality of trusses includes adjustable arms to hold in position any size truss selected during the selecting step.  
   
   
       23 . The method of  claim 22 , wherein the means for aligning the plurality of fillers with the plurality of trusses includes adjustable fingers for holding at least one of the fillers in position during the pressing step.