Composite wall panel assembly and method of production

Static structures (e.g. – buildings) – With synthetic resinous component – Foam

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Details

52404, 5230911, 52741, 52809, 52813, E04C 100

Patent

active

041470044

ABSTRACT:
An outer skin or facing of wood sheet material and an inner skin or facing of wood sheet material are adhesively bonded to opposite sides of a core of rigid expanded foam material to form an elongated wall unit having a horizontal length greater than its vertical height. A longitudinally extending upper portion of the wall unit incorporates adhesively bonded members which form an integral continuous beam extending horizontally from one end of the wall unit to the opposite end. The integral beam has a vertical height substantially greater than its thickness for supporting a substantial load above a door or window opening which may be subsequently formed within the wall unit at any selected location between the ends of the wall unit. A plurality of spaced wood furring strips are adhesively bonded to the inner facing of the wall unit and are provided with channels adjacent the inner facing for receiving electrical wiring. The furring strips also function to strengthen the wall unit against wind deflection and provide for an air space between the inner facing and gypsum dry wall sheeting which is subsequently attached to the furring strips. In one embodiment, the beam is formed by wood members which are vertically spaced between the facings to form a box beam. In another embodiment, thin sheets of metal are bonded by adhesive to the inner surfaces of the facings and to the foam core panels which are uniform in thickness throughout the entire wall unit.

REFERENCES:
patent: 3113401 (1963-12-01), Rose
patent: 3147336 (1964-09-01), Mathews
patent: 3228158 (1966-01-01), Russell
patent: 3462897 (1969-08-01), Weinrott
patent: 3689681 (1972-09-01), Searer et al.
patent: 3736715 (1973-06-01), Krumwiede
patent: 3964228 (1976-06-01), Nilsen

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