Method of manufacturing poly-bonded framed panels

Abstract

A method of manufacturing a single layer building panel. The building panels include a peripheral frame having vertical and horizontal members. One or more surfaces of the building panel can be configured with a fiber reinforced layer. The building panels can be manufactured with electrical components. The building panels can also be manufactured with openings for windows, doors and the like. The interior of the panel can include a mesh material disposed therein.

1 . A method of fabricating a building panel having structural integrity comprising:
 placing a peripheral frame in a mold press having sidewalls, a top platen and a bottom platen,   placing dry fiber on one of the top platen or bottom platen,   closing the top platen,   injecting foam into the mold press and within the peripheral frame; and   allowing the foam to cure.   
   
   
       2 . The method according to  claim 1 , wherein the structural integrity of the building panel is derived from the bonding of the foam to the peripheral frame. 
   
   
       3 . The method according to  claim 1 , wherein the foam comprises a thermoplastic material or a thermoset material. 
   
   
       4 . The method according to  claim 1 , wherein the peripheral frame can be automatically fabricated based on input received from a file having the structural design of structure using building panels. 
   
   
       5 . The method according to  claim 1 , wherein the peripheral frame includes a top horizontal stud member, a bottom horizontal stud member, a left vertical stud member, and a right vertical stud member. A first end portion of the top horizontal stud member joins to a first end portion of left vertical stud member, a second end of the top horizontal stud member joins to a first end portion of right vertical stud member, a first end portion of the bottom horizontal stud member joins to a second end portion of left vertical stud member, and a second end portion of the bottom horizontal stud member joins to a second end of the right vertical stud member. 
   
   
       6 . The method according to  claim 1 , wherein the top horizontal stud member, the bottom horizontal stud member, the right vertical stud member, and the left vertical stud member are configured as one of: a convention stud, and a c-shaped stud. 
   
   
       7 . The method according to  claim 1 , wherein a first side of the foam defines an exterior surface of the building panel and a second side of the foam defines an interior surface of the building panel. 
   
   
       8 . The method according to  claim 1 , wherein the top horizontal stud member, the bottom horizontal stud member, the right vertical stud member, and the left vertical stud member is constructed from one of: metal, aluminum, wood, and plastic. 
   
   
       9 . The method according to  claim 1 , wherein the peripheral frame is configured with an opening for any one of: a window and a door. 
   
   
       10 . The method according to  claim 1 , wherein the peripheral frame is configured with an electrical component including any one of: a switch, a conduit for wiring, and an outlet. 
   
   
       11 . The method according to  claim 1 , further comprising opening the top platen and removing the building panel from the mold press. 
   
   
       12 . The method according to  claim 1 , further comprising placing a release agent on the surface of any one of the top platen and bottom platen that engages with the foam. 
   
   
       13 . The method according to  claim 1 , wherein dry fiber is placed on both the top platen and bottom platen. 
   
   
       14 . A building panel including studs used in construction manufactured according to the method of  claim 1  comprising:
 a peripheral frame configured with the studs, wherein the studs include a top horizontal stud member, a bottom horizontal stud member, a left vertical stud member, and a right vertical stud member, wherein a portion of the top horizontal stud member joins to a portion of left vertical stud member, a portion of the top horizontal stud member joins to a portion of right vertical stud member, a portion of the bottom horizontal stud member joins to a portion of left vertical stud member, and a portion of the bottom horizontal stud member joins to a portion of the right vertical stud member; and   a foam formed at least within the peripheral frame, wherein the foam is bonded to the peripheral frame, a first side of the foam having fiber impregnated with the foam defines a first surface of the building panel, and a second side of the foam defines an a second surface of the building panel.