Composite Sandwich Wall Panel

Abstract

The present invention relates to a composite sandwich wall panel comprising: at least two fine sand gypsum or concrete panels (I) in each of which a glass fiber web ( 2 ) is disposed at center, and at least one polystyrene panel ( 3 ), which are bonded alternatively. The surface layer and the bottom layer are the fine sand gypsum or concrete panels, and according to the requirement, the wall panel can be produced to have three or more layers of composite panels. The wall panel of the present invention has advantages of light weight, easy installation, strong loading capacity, no seam crack, no plaster, and good performance of thermal insulation, sound insulation and fireproof as well as it is suitable for internal wall and external wall.

1 - 7 . (canceled) 
     
     
         8 . A wall panel having at least four edges and comprised of at least two primary layers comprised of a fiberglass mesh disposed in a mix and at least one secondary layer of lightweight material disposed between said primary layers. 
     
     
         9 . The wall panel of  claim 8  wherein there are two said primary layers, a first primary layer forming a front of said wall panel and a second primary layer forming a back of said wall panel, further comprising a single said secondary layer disposed between said primary layers, thereby providing a modular wall panel. 
     
     
         10 . The wall panel of  claim 8  wherein there are three said primary layers, a first primary layer forming a front of said wall panel, a second said primary layer forming a central layer, and a third primary layer forming a back of said wall panel, further comprising two said secondary layers disposed between said primary layers, thereby providing a modular wall panel. 
     
     
         11 . The wall panel of  claim 8  wherein said mix is selected from the group consisting of fine sand and gypsum; pure gypsum; and fine sand and cement, for building construction. 
     
     
         12 . The wall panel of  claim 8  wherein said lightweight material is polystyrene foam. 
     
     
         13 . The wall panel of  claim 8  wherein said primary layers are comprised of 10% to 30% by weight fine sand with a grain size between 0.25 and 1.5 mm. 
     
     
         14 . The wall panel of  claim 10  wherein said primary layers are between 8 and 12 mm thick. 
     
     
         15 . The wall panel of  claim 10  wherein said fiberglass mesh has an eyelet size between 3 mm by 3 mm and 5 mm by 5 mm. 
     
     
         16 . The wall panel of  claim 10  wherein said central layer extends beyond one edge of said panel, thereby forming a tongue. 
     
     
         17 . The wall panel of  claim 16  wherein said central layer is recessed along a side of said panel thereby forming a groove adapted to receive said tongue, such that a close-fitting joint is formed between adjacent, installed said panels. 
     
     
         18 . The wall panel of  claim 17  wherein said fiberglass mesh extends from all four edges of said panel. 
     
     
         19 . The wall panel of  claim 17  wherein said tongue and said groove have sides substantially perpendicular to said edge and are thereby adapted to connect in a tight fitting manner. 
     
     
         20 . The wall panel of  claim 18  wherein said fiberglass mesh extends between 15 mm and 35 mm from a left and right edge of said panel, and between 30 mm and 60 mm from a top and bottom of said panel, thereby providing structural support to said joints. 
     
     
         21 . The wall panel of  claim 8  wherein said panel is adapted for installation as an external wall panel with an interior face suitable for supporting hanging items and paint or wall paper. 
     
     
         22 . The wall panel of  claim 8  wherein said mix comprises between 0.15% and 0.3% methylcellulose ether and between 0.5% and 1.5% redispersable powder which is a combination of the chemical additives of: vinyl acetate; ethylene copolymer; ethylene; vinyl laurate; and vinyl chloride terpolymer are components of said mix. 
     
     
         23 . The wall panel of  claim 18  wherein said fiberglass mesh is adapted to overlap said fiberglass mesh extending from other wall panels during installation. 
     
     
         24 . The wall panel of  claim 23  wherein a plurality of said panels are attached to each other by said tongue and groove edges interlocking and being reinforced by said overlapping fiberglass mesh thereby forming a continuous, seamless wall which is load bearing, fire resistant, and soundproof. 
     
     
         25 . The wall panel of  claim 8  wherein there are four said primary layers, a first primary layer forming a front of said wall panel, a second and the third primary layers forming the intermediate central layers, a four primary layer forming a back of said wall panel, further comprising three said secondary layers disposed between said four primary layers, thereby providing a modular wall panel. 
     
     
         26 . A method of building a wall from modular wall panels having a fiberglass mesh extending beyond all four edges of said panel, a tongue extending from one side edge and a groove in the opposite side edge, comprising the steps of:
 a) inserting a tongue of a second panel in a groove of a first panel and overlapping the fiberglass mesh of the two panels thereby creating a joint;   b) fixing the two said fiberglass mesh together;   c) covering said joint with joint filler of the same materials; and   d) repeating steps (a) to (c) to create a wall.   
     
     
         27 . The method of  claim 26  comprising the additional steps of affixing said fiberglass mesh extending from a bottom edge of said panel to the top of the connecting panel below or to a floor, and affixing said fiberglass mesh extending from a top edge of said panel to the bottom of the connecting panel above or to a ceiling.