Patent ID: 8012301
Filing Date: 2011-09-06
Classification: B29C,B29D,B29L,B32B,E02D,E04B,E04C,Y10T

Abstract:
1. A method of manufacturing a precursor to a load bearing structural building panel, comprising: (a) depositing a first fibrous layer onto a support, the first fibrous layer having a first side edge, a second side edge, a width defined between the first and second side edges, a length perpendicular to the width, and a top surface; (b) placing foam along the length of, and across the width of, the first fibrous layer thereby to develop a construct having a foam layer extending along the length of, and generally overlying the width of, the first layer, the construct having first and second sides, a construct length, and a width between the first and second sides, the foam layer defining a top surface of the construct opposite the first layer; (c) depositing pre-fabricated load-bearing studs on the top surface of the construct, the studs extending generally away from the first layer and away from the foam layer, with the foam layer between the studs and the first layer, and thereby defining a plurality of recesses between the studs; and (d) depositing a second fibrous layer onto the top surface of the construct, covering the width of the construct, including overlying and contacting each of the load-bearing studs and overlying and contacting the foam layer in the recess, thereby to develop a precursor to the building panel, having a thickness between the first and second layers, and wherein a surface of the second layer, which faces away from the foam layer, defines stud profiles and channel profiles which reflect the studs as deposited and the recesses so defined by the studs and the foam layer.