Patent ID: 8287671

Claim:
A method for fabricating a fire retardant, thermally insulative vandalism and damage resistant composite panel having a low density foam inner layer and a high density foam outer layer bounding and bonded to the inner layer at the interface therebetween that is undercut at an angle at opposing panel edges, for use as a portion of a building exterior, comprising the steps of: a. supplying a viscous low density foam material, defining the foam inner layer of the panel, to an interior area of a frame in an amount sufficient to cover the interior area enclosed by the frame but insufficient to fill the frame; b. supplying a viscous high density foam material, defining the foam outer layer of the panel, to the interior of the frame in an amount sufficient to contact and cover the low density foam material enclosed by the frame but insufficient to fill the frame; c. contacting the entirety of an exposed surface of the high density foam within the frame with a fabric having sufficiently high porosity for migration thereinto of the high density foam material for mechanical bonding with the fabric before complete curing of the high density foam material occurs; d. supplying an exterior material to the interior of the frame in an amount sufficient to cover the entirety of the fabric for migration into and through the fabric of a sufficient amount of the exterior material to mechanically bond with the fabric and high density foam and to chemically bond with the high density foam material at the previously exposed surface thereof before complete curing of the high density foam material occurs.