Patent ID: 8863456

Claim:
A composite structural insulated panel comprising: an exterior veneer; an interior veneer; and a glass-fiber-reinforced concrete shell comprising: a first glass-fiber-reinforced concrete shell layer disposed adjacent to the exterior veneer and between the exterior veneer and a face of an insulating foam core; and a second glass-fiber-reinforced concrete shell layer disposed adjacent the interior veneer and between the interior veneer and an opposite face of the insulating foam core; the insulating foam core comprising a preformed expanded foam, and being sandwiched between the first and second glass-fiber-reinforced concrete shell layers, at least the outside peripheral edges of the insulating foam core being encapsulated by the glass-fiber-reinforced concrete shell layers; where substantially all reinforcing glass-fibers of the glass-fiber reinforced concrete shell are randomly oriented and homogeneously distributed throughout the shell; the veneers and glass-reinforced concrete shell layers being sequentially formed in a wet-on-wet fabrication technique to result in increased adhesion between the veneers and the glass-fiber-reinforced concrete shell layers, forming distinct layers of interior veneer, exterior veneer, and the adjacent glass-reinforced concrete shell layers.