Patent ID: 7922954

Claim:
A method for making a building wall panel comprising the steps of: (1) forming a hollow core element from strips of a fluted web material bonded together to form a rectangular core panel having a front face and a rear face with the flutes oriented perpendicular to the faces; (2) providing an enclosing peripheral frame for the core panel; (3) filling the frame to a selected depth with a first liquid gypsum layer; (4) pressing the core panel with the front face facing downwardly into the liquid gypsum layer within the frame to force the liquid gypsum into a portion of the hollow core element at said front face; (5) allowing the liquid gypsum to set sufficiently to form the building wall panel having a self-supporting gypsum layer and the frame comprising an integral part of the building wall panel; (6) removing the core panel and first gypsum layer from the frame; (7) filling the frame to a selected depth with a second liquid gypsum mixture; (8) inverting the core panel; (9) pressing the other face of the core panel into the second liquid gypsum mixture to force the liquid gypsum into a portion of the hollow core element at said other face; and (10) allowing the liquid gypsum in the other face portion of the panel to dry sufficiently to form the building wall panel having a second self-supporting gypsum layer.