Construction system and resilient non-woven structural building panels

Abstract

A construction system is based on a plurality of interlocking panels, each panel formed of a non-woven, needle-punched, thermo-mechanically compacted fabric, each panel having dual density gradients, a first density gradient extending from the first outer surface to the center of panel and a second density gradient extending from the center of the panel to the outer surface, wherein less dense sections of each panel provide acoustic and thermal insulating properties and more dense sections of each panel provide strength and load-bearing properties.

1 . A construction system comprising:
 a plurality of interlocking panels, each panel comprising a non-woven, needle-punched, thermo-mechanically compacted fabric, each panel having a first outer surface and an opposed second outer surface,   each panel having dual density gradients, a first density gradient extending from the first outer surface to the center of panel and a second density gradient extending from the center of the panel to the outer surface,   wherein less dense sections of each panel provide acoustic and thermal insulating properties and more dense sections of each panel provide strength and load-bearing properties.   
   
   
       2 . The construction system set forth in  claim 1  wherein the non-woven fabric comprises fibers derived from at least one polymer selected from the group consisting of polyolefins, polyesters, PET and copolymers thereof, PBT, polyamides, aramids, cotton, flax, and hemp. 
   
   
       3 . The construction system set forth in  claim 1  wherein at least one of the first outer surface and the second outer surface further includes a coating selected from the group consisting of polyolefins, polyesters, PET and copolymers thereof, PBT, polyamides, and aramids. 
   
   
       4 . The construction system set forth in  claim 1  wherein at least some of the panels contain a piezoelectric material in fiber or film form to render the panel capable of sensing and responding to at least one form of environmental stimulation selected from sound waves, other pressure waves, and temperature. 
   
   
       5 . The construction system set forth in  claim 2  wherein at least some of the fibers of the non-woven fabric comprise co-linear channels that extend along the fiber length for improved thermal and acoustic insulation and moisture transport. 
   
   
       6 . The construction system set forth in  claim 1  wherein the dual density gradient of at least some of the panels is formed by the panel comprising two thinner panels sandwiched together wherein the sandwiched panels are of at least two differing densities, thereby providing the density gradient. 
   
   
       7 . The construction system set forth in  claim 1  wherein at least some of the panels are cut into shapes that allow direct construction of non-traditionally shaped buildings selected from orthogonal, angular, and dome-like buildings. 
   
   
       8 . A construction method comprising the steps of:
 providing a plurality of interlocking panels, each panel having a first outer surface and an opposed second outer surface, each panel made by the process comprising the steps of:
 forming a non-woven fabric from individual fibers, 
 needle-punching the non-woven fabric in order to further entangle the fibers; and 
 thermo-mechanically compacting the needle-punched, non-woven fabric; 
   each panel having dual density gradients, a first density gradient extending from the first outer surface to the center of the panel and a second density gradient extending from the center of the panel to the second outer surface,   wherein less dense sections of each panel provide acoustic and thermal insulating properties and more dense sections of each panel provide strength and load-bearing properties; and   assembling a low-rise building by interlocking the panels.   
   
   
       9 . The construction method of  claim 8  wherein the non-woven fabric is formed of fibers derived from at least one polymer selected from the group consisting of polyolefins, polyesters, PET and copolymers thereof, PBT, polyamides, aramids, cotton, flax, and hemp. 
   
   
       10 . The construction method of  claim 8  wherein the non-woven fabric is formed of thermoplastic fibers and further including the step of forming raceways within the interlocked panels with a hot bar, the hot bar having a temperature exceeding the melting temperature of the thermoplastic fibers, the raceways providing means for running utility lines and plumbing throughout the building.