Apparatus and methods for prefabricated building skin system exterior wall panels

Abstract

Apparatus, systems, and methods for a prefabricated building skin system including a composite external wall panel. The external wall panel may include an inner skin forming a first side of the external wall panel and an outer skin forming a second side of the external wall panel. A fiber reinforced polymer is wrapped around a panel edge connecting the inner skin and the outer skin. A foam center may be disposed between the inner skin and the outer skin. A thermoset resin may be infused into the composite external wall panel. At least one steel connector integrated between the inner skin and the outer skin. The steel connector may be connectable to a building column, wherein the steel connector is configured to support a vertical load.

What is claimed is: 
     
         1 . A prefabricated building skin system comprising:
 a composite external wall panel including:
 an inner skin forming a first side of the external wall panel; 
 an outer skin forming a second side of the external wall panel; wherein a fiber reinforced polymer is wrapped around a panel edge connecting the inner skin and the outer skin; 
 a foam center disposed between the inner skin and the outer skin, 
 a thermoset resin infused into the composite external wall panel; and 
 at least one steel connector integrated between the inner skin and the outer skin, the steel connector connectable to a building column, wherein the steel connector is configured to support a vertical load. 
   
     
     
         2 . The prefabricated building skin system of  claim 1 , wherein the steel connector is connectable to the building column by a single point connection on each column. 
     
     
         3 . The prefabricated building skin system of  claim 1 , further comprising a maximum deflection of a span length divided by 400 when subjected to at least one of an erection load, a service load, or a dead load. 
     
     
         4 . The prefabricated building skin system of  claim 1 , wherein the inner skin and the outer skin comprise fiberglass and thermoset resin. 
     
     
         5 . The prefabricated building skin system of  claim 1 , further comprising a rain screen covering the outer skin. 
     
     
         6 . The prefabricated building skin system of  claim 1 , further comprising a gel finish on the outer skin. 
     
     
         7 . The prefabricated building skin system of  claim 1 , further comprising a painted finish on the outer skin. 
     
     
         8 . The prefabricated building skin system of  claim 1 , further comprising a brick finish on the outer skin. 
     
     
         9 . The prefabricated building skin system of  claim 1 , wherein the fiber reinforced polymer is vacuum infused with the thermoset resin. 
     
     
         10 . The prefabricated building skin system of  claim 1 , further comprising at least one inner frame. 
     
     
         11 . The prefabricated building skin system of  claim 10 , further comprising a glazing disposed within the inner frame. 
     
     
         12 . A method for assembling a prefabricated building skin system, the method comprising:
 forming, at a first location, an external wall panel by:
 positioning a fiberglass wrapping around a foam core; the foam core disposed between an inner skin and outer skin; 
 integrating a steel connector into the external wall panel; and 
 integrating a thermoset resin into the wall panel by vacuum infusing the resin, wherein an atmospheric pressure differential from the vacuum pushes the resin through a void space in the external wall panel; 
   applying, at the first location, a finish to the external wall panel; and   connecting the external wall panel to a building column at a second location.   
     
     
         13 . The method of  claim 12 , wherein the finish is applied to the outer skin. 
     
     
         14 . The method of  claim 12 , wherein the finish includes a brick finish. 
     
     
         15 . The method of  claim 12 , wherein the finish includes a rain screen. 
     
     
         16 . The method of  claim 12 , wherein the finish includes a paint. 
     
     
         17 . The method of  claim 12 , further comprising connecting the steel connector to the building column through an attachment bracket. 
     
     
         18 . The method of  claim 12 , wherein the external wall panel has a maximum deflection of a span length divided by 400 when subjected to at least one of an erection load, a service load, or a dead load. 
     
     
         19 . The method of  claim 12 , further comprising an inner frame. 
     
     
         20 . The method of  claim 19 , further comprising applying a glazing disposed within the inner frame.