Building Component and Method

Abstract

According to an aspect of the invention, a building component includes a central layer, such as a foam panel, having first and second opposite faces, and a hardened surface, such as a concrete-based substance, applied to at least one of the faces of the foam layer. The foam layer can include at least one channel. The hardened surface is applied to the face such that it extends within the channel. The building component can also include a reinforcing member, such as a length of rebar, disposed within the channel. A process of fabricating a building component includes providing the foam layer, and applying the hardened surface to at least one of the faces of the foam layer.

1 . A building component, comprising:
 a central layer having first and second opposite faces; and   a hardened surface applied to at least one of the faces of the central layer.   
   
   
       2 . The building component of  claim 1 , wherein the central layer is a foam panel. 
   
   
       3 . The building component of  claim 1 , wherein the central layer includes at least one channel within the first face, wherein the hardened surface is applied to the first face and extends within the at least one channel. 
   
   
       4 . The building component of  claim 3 , wherein the at least one channel has a transverse cross-section having a geometric shape selected from the group consisting of triangular, semicircular, rectangular, and tee. 
   
   
       5 . The building component of  claim 3 , wherein the central layer includes a plurality of the channels within the first face, wherein the channels are mutually substantially parallel. 
   
   
       6 . The building component of  claim 3 , wherein the central layer includes a plurality of the channels within the first face, wherein the channels form a grid. 
   
   
       7 . The building component of  claim 6 , wherein the grid includes a first set of channels that are mutually substantially parallel, and a second set of channels that are mutually substantially parallel and substantially perpendicular to the first set of channels. 
   
   
       8 . The building component of  claim 3 , wherein the central layer also includes at least one channel within the second face, wherein the hardened surface is applied to the second face and extends within the at least one channel. 
   
   
       9 . The building component of  claim 3 , further comprising a reinforcing member disposed within the at least one channel. 
   
   
       10 . The building component of  claim 9 , wherein the reinforcing member is a length of rebar. 
   
   
       11 . The building component of  claim 1 , wherein the hardened surface is a concrete-based substance. 
   
   
       12 . A building structure, comprising a plurality of the building components as recited in  claim 1 . 
   
   
       13 . A process of fabricating a building component, comprising:
 providing a central layer having first and second opposite faces; and   applying a hardening material to at least one of the faces of the central layer.   
   
   
       14 . The process of  claim 13 , wherein the central layer is a foam panel. 
   
   
       15 . The process of  claim 13 , further comprising forming at least one channel within the first face, and applying the hardening material to the first face such that the hardening material extends within the at least one channel. 
   
   
       16 . The process of  claim 15 , further comprising forming the at least one channel to have a transverse cross-section having a geometric shape selected from the group consisting of triangular, semicircular, rectangular, and tee. 
   
   
       17 . The process of  claim 15 , comprising forming a plurality of the channels within the first face, such that the channels are mutually substantially parallel. 
   
   
       18 . The process of  claim 15 , comprising forming the plurality of the channels within the first face such that the channels form a grid. 
   
   
       19 . The process of  claim 18 , comprising forming the grid to include a first set of channels that are mutually substantially parallel, and a second set of channels that are mutually substantially parallel and substantially perpendicular to the first set of channels. 
   
   
       20 . The process of  claim 15 , further comprising forming at least one channel within the second face, and applying the hardening material to the second face such that the hardened surface extends within the at least one channel. 
   
   
       21 . The process of  claim 15 , further comprising disposing a reinforcing member within the channel. 
   
   
       22 . The process of  claim 21 , wherein the reinforcing member is a length of rebar. 
   
   
       23 . The process of  claim 13 , wherein the hardening material is a concrete-based substance. 
   
   
       24 . The process of  claim 13 , wherein applying the hardening material to at least one of the faces of the central layer includes applying a viscous material to the at least one of the faces of the central layer, and allowing the viscous material to harden. 
   
   
       25 . The process of  claim 24 , further comprising allowing the hardened material to cure. 
   
   
       26 . The process of  claim 24 , further comprising finishing the outer surface of the hardened material. 
   
   
       27 . A process of constructing a building structure, comprising assembling a plurality of building components including the building components fabricated according to  claim 13 .