Mould resistant sandwich panel

Abstract

A mould resistant sandwich panel includes a plurality of frame members having opposed faces and opposed sides. Mineral board sheets secured to the opposed sides of the frame members, thereby creating a plurality of interior compartments. Either mineral foam, concrete foam or concrete is used to fill each of the interior compartments.

1 . A mould resistant sandwich panel, comprising: 
 a plurality of frame members having opposed faces and opposed sides;    mineral board sheets secured to the opposed sides of the frame members, thereby creating a plurality of interior compartments; and    one of mineral foam, concrete foam or concrete filling each of the interior compartments.    
   
   
       2 . The mould resistant sandwich panel of  claim 1 , wherein apertures extend through the frame members between the opposed faces.  
   
   
       3 . The mould resistant sandwich panel of  claim 2 , wherein the apertures are knockout apertures.  
   
   
       4 . The mould resistant sandwich panel of  claim 2 , wherein the apertures are adapted to receive electrical conduit.  
   
   
       5 . The mould resistant sandwich panel of  claim 2 , wherein the apertures are adapted to receive plumbing pipe.  
   
   
       6 . The mould resistant sandwich panel of  claim 2 , wherein the apertures are adapted to allow the one of mineral foam, concrete foam or concrete to flow between interior compartments when filling the interior compartments with the one of mineral foam, concrete foam or concrete.  
   
   
       7 . The mould resistant sandwich panel of  claim 2 , wherein the apertures are adapted to receive rebar to reinforce the one of mineral foam, concrete foam or concrete.  
   
   
       8 . The mould resistant sandwich panel of  claim 1 , wherein a reinforcing mesh is positioned between the mineral board sheets to reinforce the one of mineral foam, concrete foam or concrete.  
   
   
       9 . The mould resistant sandwich panel of  claim 8 , wherein spacer elements are included to space the reinforcing mesh from the mineral board sheets.  
   
   
       10 . A mould resistant sandwich panel comprising: 
 a plurality of frame members having opposed faces and opposed sides, the frame members comprising flow apertures and aligned apertures;    mineral board sheets secured to the opposed sides of the frame members, thereby creating a plurality of interior compartments;    one of mineral foam, concrete foam or concrete filling each of the interior compartments, the flow apertures adapted to allow the one of mineral foam, concrete foam or concrete to flow between the interior compartments during filling;    a reinforcing mesh positioned between the mineral board sheets to reinforce the one of mineral foam, concrete foam or concrete;    spacer elements to space the reinforcing mesh from the mineral board sheets; and    at least one of electrical conduit and plumbing pipe extending through the aligned apertures.    
   
   
       11 . A method of fabricating a mould resistant sandwich panel, the method comprising the steps of: 
 providing a plurality of frame members having opposed faces and opposed sides;    securing mineral board sheets to the opposed sides of frame members to create a plurality of interior compartments; and    filling the interior compartments with one of mineral foam, concrete foam or concrete.    
   
   
       12 . The method of  claim 11 , wherein providing a plurality of frame members comprises providing a plurality of frame members having apertures that extend between the opposed faces.  
   
   
       13 . The method of  claim 12 , wherein filling the interior compartments comprises the one of mineral foam, concrete foam or concrete flowing between compartments through the apertures.  
   
   
       14 . The method of  claim 12 , further comprising the step of extending at least one of electrical conduit, plumbing pipe, and rebar through the apertures prior to filling the interior compartments with the one of mineral foam, concrete foam or concrete.  
   
   
       15 . The method of  claim 11 , further comprising the step of positioning a reinforcing mesh within the interior compartments prior to filling the interior compartments with the one of mineral foam, concrete foam or concrete.