Structural panels

Abstract

A panel is disclosed, which comprises a core and first and second plates disposed on opposing sides of the core. The core may comprise pluralities of first and second rib structures, a foamed polymer structure, or a honeycomb structure. The panel may be used as a building or construction structure or in a concrete pouring application.

1 . A structural panel for use as a building or construction structure, the structural panel comprising:
 a core comprising a corrugated composite structure; and   first and second plates disposed on opposing sides of the core,   wherein the core comprises a plurality of first rib structures running along a first direction that is disposed on the first plate and a plurality of second rib structures running along a second direction that is disposed on the plurality of first rib structures.   
   
   
       2 . The structural panel of  claim 1 , wherein the first direction is substantially perpendicular to the second direction. 
   
   
       3 . The structural panel of  claim 1 , wherein the pluralities of the first and second rib structures have a cross-sectional shape in a form of one of the following: rectangle, square, triangle, trapezoid, and I-shape. 
   
   
       4 . The structural panel of  claim 1 , wherein the pluralities of the first and second rib structures each has a height in a range of about 3 mm to about 9 mm and a width in a range of about 3 mm to about 9 mm. 
   
   
       5 . The structural panel of  claim 1 , wherein the first rib structures are spaced about 2 mm to about 6 mm from one another. 
   
   
       6 . The structural panel of  claim 5 , wherein the second rib structures have the same spacing as the first rib structures. 
   
   
       7 . The structural panel of  claim 1 , wherein the pluralities of the first and second rib structures are formed of polypropylene. 
   
   
       8 . The structural panel of  claim 1 , wherein the plates are formed from aluminum or steel. 
   
   
       9 . The structural panel of  claim 1 , wherein overall thickness of the structural panel is from about ½ inches to about 1 inches. 
   
   
       10 . The structural panel of  claim 1 , wherein the structural panel is part of one of the following: an interior wall, an exterior wall, a floor, a roof, a deck, a platform, a pallet, a tilt-up wall, a bulkhead, a marine sheet piling, a highway sound barrier, a trailer, a home, and a shipping container. 
   
   
       11 . The structural panel of  claim 1 , further comprising at least one laminated layer disposed on one of the first and second plates. 
   
   
       12 . The structural panel of  claim 11 , wherein the at least one laminated layer is one of the following: real or faux brick, stone, wood, stucco, acoustical tiles, wood panels, paint, and plaster moldings. 
   
   
       13 . The structural panel of  claim 11 , wherein the at least one laminated layer is a flexible membrane comprising a thermoplastic material suitable for use against poured concrete mixes. 
   
   
       14 . The structural panel of  claim 13 , wherein the flexible membrane comprises a composite of high density polyethylene, alumina, and carbon black. 
   
   
       15 . The structural panel of  claim 1 , wherein the structural panel is part of a concrete forming structure for concrete pouring applications. 
   
   
       16 . A structural panel for use as a building or construction structure, the structural panel comprising:
 a core comprising a foamed polymer structure;   a first sheet and a second sheet, wherein the first and second sheets are polyethylene terephthalate polyester sheets or polyester sheets; and   first and second plates disposed on opposing sides of the core,   wherein the first sheet is inserted between the core and the first plate and the second sheet is inserted between the core and the second plate.   
   
   
       17 . The structural panel of  claim 16 , wherein the foamed polymer structure is polyvinyl chloride foam. 
   
   
       18 . The structural panel of  claim 16 , wherein the foamed polymer structure has a height in a range of about ⅜ inches to about 1 inch. 
   
   
       19 . The structural panel of  claim 16 , wherein the plates are formed from polyester or metal. 
   
   
       20 . The structural panel of  claim 16 , further comprising at least one laminated layer which is a flexible membrane disposed on at least one of the first and second plates. 
   
   
       21 . The structural panel of  claim 20 , wherein the flexible membrane comprises one of the following: ethylene propylene and a diene monomer; a terpolymer of ethylene, propylene and a diene monomer; a polymer comprising butylene monomers; a polymer comprising chlorosulfonated polyethylene; or a combination thereof. 
   
   
       22 . The structural panel of  claim 20 , wherein the flexible membrane comprises a thermoplastic material suitable for use with poured concrete. 
   
   
       23 . The structural panel of  claim 22 , wherein the flexible membrane comprises a composite of high density polyethylene, alumina, and carbon black. 
   
   
       24 . A method of forming a concrete structure, comprising the steps of:
 forming a concrete forming structure into which uncured concrete is to be poured, wherein the concrete forming structure comprises at least one panel having a core and first and second plates disposed on opposing sides of the core;   pouring concrete into the concrete forming structure; and   removing the concrete forming structure after the concrete has cured,   wherein the core comprises a plurality of first rib structures running along a first direction that is disposed on the first plate and a plurality of second rib structures running along a second direction that is disposed on the plurality of first rib structures.   
   
   
       25 . The method of forming a concrete structure of  claim 24 , wherein the first direction is substantially perpendicular to the second direction. 
   
   
       26 . The method of forming a concrete structure of  claim 24 , wherein the pluralities of the first and second rib structures have a cross-sectional shape in the form of one of the following: rectangle, square, triangle, trapezoid, and I-shape. 
   
   
       27 . The method of forming a concrete structure of  claim 24 , wherein the pluralities of the first and second rib structures each has a height in a range of about 3 mm to about 9 mm and a width in a range of about 3 mm to about 9 mm. 
   
   
       28 . The method of forming a concrete structure of  claim 24 , wherein the first rib structures are spaced about 2 mm to about 6 mm from one another. 
   
   
       29 . The method of forming a concrete structure of  claim 28 , wherein the second rib structures have the same spacing as the first rib structures. 
   
   
       30 . The method of forming a concrete structure of  claim 24 , wherein the pluralities of the first and second rib structures are formed of polypropylene. 
   
   
       31 . The method of forming a concrete structure of  claim 24 , wherein the plates are formed from aluminum or steel. 
   
   
       32 . The method of forming a concrete structure of  claim 24 , wherein overall thickness of the structural panel is from about ½ inches to about 1 inches. 
   
   
       33 . The method of forming a concrete structure of  claim 24 , further comprising at least one laminated layer disposed on one of the first and second plates. 
   
   
       34 . The method of forming a concrete structure of  claim 33 , wherein the at least one laminated layer is a flexible membrane comprising one of the following: ethylene propylene and a diene monomer; a terpolymer of ethylene, propylene and a diene monomer; a polymer comprising butylene monomers; a polymer comprising chlorosulfonated polyethylene; or a combination thereof. 
   
   
       35 . A method of forming a concrete structure, comprising the steps of:
 forming a concrete forming structure into which uncured concrete is to be poured, wherein the concrete forming structure comprises at least one panel having a core, first and second plates disposed on opposing sides of the core, and a laminated layer disposed on one of the first and second plates that contact the uncured concrete;   pouring concrete into the concrete forming structure; and   removing the concrete forming structure after the concrete has cured,   wherein the at least one laminated layer is a flexible membrane comprising a thermoplastic material suitable for use against poured concrete.   
   
   
       36 . The method of forming a concrete structure of  claim 35 , wherein the flexible membrane comprises a high density polyethylene, alumina, and carbon black. 
   
   
       37 . The method of forming a concrete structure of  claim 35 , wherein the core comprises a foamed polymer structure. 
   
   
       38 . The method of forming a concrete structure of  claim 37 , wherein the foamed polymer structure is polyvinyl chloride foam. 
   
   
       39 . The method of forming a concrete structure of  claim 37 , wherein the foamed polymer structure has a height in a range of about ⅜ inches to about 1 inch. 
   
   
       40 . The method of forming a concrete structure of  claim 37 , wherein the plates are formed from polyester or metal. 
   
   
       41 . The method of forming a concrete structure of  claim 37 , further comprising a first sheet inserted between the core and the first plate and a second sheet inserted between the core and the second plate, wherein the first and second sheets are polyethylene terephthalate polyester sheets or polyester sheets. 
   
   
       42 . The method of forming a concrete structure of  claim 35 , wherein the core comprises a plurality of first rib structures running along a first direction that is disposed on the first plate and a plurality of second rib structures running along a second direction that is disposed on the plurality of first rib structures 
   
   
       43 . The method of forming a concrete structure of  claim 42 , wherein the first direction is substantially perpendicular to the second direction. 
   
   
       44 . The method of forming a concrete structure of  claim 42 , wherein the pluralities of the first and second rib structures have a cross-sectional shape in a form of one of the following: rectangle, square, triangle, trapezoid, and I-shape. 
   
   
       45 . The method of forming a concrete structure of  claim 42 , wherein the pluralities of the first and second rib structures are formed of polypropylene. 
   
   
       46 . The method of forming a concrete structure of  claim 42 , wherein the plates are formed from aluminum or steel. 
   
   
       47 . The method of forming a concrete structure of  claim 35 , wherein the core comprises a honeycomb structure. 
   
   
       48 . The method of forming a concrete structure of  claim 47 , wherein the honeycomb structure is formed from metal.