Structural elements and method for fabricating structural elements

Abstract

A composite panel structure includes a flange beam assembly including: a web assembly; and a first flange assembly attached in an essentially perpendicular fashion to the web assembly. The composite panel structure further includes at least two panel assemblies. Each panel assembly includes: a foam layer; a first high-density material layer secured to the foam layer; and at least one recess configured to receive at least a portion of the first flange assembly.

1 . A composite panel structure comprising: 
 a flange beam assembly including: 
 a web assembly; and  
 a first flange assembly attached in an essentially perpendicular fashion to the web assembly; and  
   at least two panel assemblies, wherein each panel assembly includes: 
 a foam layer;  
 a first high-density material layer secured to the foam layer; and  
 at least one recess configured to receive at least a portion of the first flange assembly.  
   
   
   
       2 . The composite panel structure of  claim 1  wherein the foam layer is at least partially constructed of a vinyl acetate-ethylene copolymer.  
   
   
       3 . The composite panel structure of  claim 1  wherein the first high-density material layer is a poly-urea material layer.  
   
   
       4 . The composite panel structure of  claim 1  wherein the first high-density material layer is a cement-based material layer.  
   
   
       5 . The composite panel structure of  claim 1  wherein the composite panel structure is selected from the group consisting of: a building wall panel structure; a roof panel structure; a ceiling panel structure; a floor panel structure; a privacy wall panel structure; a sea wall panel structure; and any combination thereof.  
   
   
       6 . The composite panel structure of  claim 1  further comprising a second high-density material layer.  
   
   
       7 . The composite panel structure of  claim 6  wherein the foam layer is disposed between the first and second high-density material layers.  
   
   
       8 . The composite panel structure of  claim 1  wherein the flange beam assembly includes a second flange assembly attached in an essentially perpendicular fashion to the web assembly.  
   
   
       9 . A method of fabricating a composite panel structure comprising: 
 providing a flange beam assembly including a web assembly and a first flange assembly attached in an essentially perpendicular fashion to the web assembly;    providing a layer of foam including at least one recess configured to receive at least a portion of the first flange assembly; and    disposing a first high-density material layer onto the layer of foam.    
   
   
       10 . The method of  claim 9  wherein the layer of foam is at least partially constructed of a vinyl acetate-ethylene copolymer.  
   
   
       11 . The method of  claim 9  wherein the composite panel structure is selected from the group consisting of a building wall panel structure, a roof panel structure, a ceiling panel structure, a floor panel structure, a privacy wall panel structure, a sea wall panel structure, and any combination thereof.  
   
   
       12 . The method of  claim 9  wherein the first high-density material layer is a poly-urea material layer.  
   
   
       13 . The method of  claim 9  wherein the first high-density material layer is a cement-based material layer.  
   
   
       14 . The method of  claim 9  further comprising disposing a second high-density material layer onto the layer of foam.  
   
   
       15 . The method of  claim 14  wherein the foam layer is disposed between the first and second high-density material layers.  
   
   
       16 . The method of  claim 9  wherein the flange beam assembly includes a second flange assembly attached in an essentially perpendicular fashion to the web assembly.