POLY-BONDED FRAMED PANELS

BACKGROUND OF THE INVENTION

Field of the Invention:

[0001] The present invention relates to a building panel, method of

fabricating the building panel, and method of constructing a build employing the

building panel. More particularly, the present invention relates to a framed building

panel, method of fabricating the framed building panel, and method of constructing

a build employing the building panel, wherein the framed building panel has

increase structural integrity and is operable to construct a wall, roof, floor, ceiling,

room, and building.

Description of the Prior Art:

[0002] The construction industry is continuously attempting to find ways to

reduce the time, cost, and labor associated with the construction of a structure, such

as a building, wall, room, floor, ceiling and roof. Techniques used to reduce the

time, cost, and labor associated with the construction of a structure includes

prefabrication of various portions of a structure. Once the portion of the structure is

fabricated, it is then transported to the construction site for placement in its intended

location. One problem with such techniques is that the prefabricated portion of the

structure is constructed with conventional materials using the techniques that would

be used on the construction site. Another problem with these techniques is that the

prefabricated portion is subject to damage during its transportation to the

construction site.

[0003] These techniques typically also require that the structural integrity of

the prefabricated portion of the building is derived solely from the frame of the

prefabricated portion. In some instances, the structural integrity of the prefabricated

portion of the building and the building itself is further derived from the specific

way a prefabricated portion needs to be assembled with another portion of the

building using connections, fasteners, and other coupling mechanisms specific to

using the prefabricated portion.

[0004] Accordingly, there is a need for a building panel having structural

integrity, a method of fabricating the building panel having structural integrity, and

method of constructing a building employing the building panel. There is a need

for the building panel having structural integrity and the method of fabricating the

building panel having structural integrity, where the structural integrity is derived

from the bonding of the foam to vertically and horizontally aligned stud members.

There is a need for the vertically and horizontally aligned studs to form a frame.

There is a need for the foam to define an interior side of the building panel and an

exterior side of the building panel. There is a need for the building panel having

structural integrity to couple to another building panel having structural integrity.

There is a need for the building panel to interlock with an adjacent building panel

employing an interlocking stud. There is a need for the building panel to be held in

an upright position employing a track secured to a floor, such as with an anchor.

SUMMARY OF THE INVENTION

[0005] According to an embodiment of the present invention, a building

panel having structural integrity, a method of fabricating the building panel having

structural integrity, and method of constructing a building employing the building

panel are provided. The building panel is a one layer building panel that derives its

structural integrity from a foam forming the layer that bonds to horizontal and

vertical stud members. The vertical members can be provided at the edges of the

building panel. The horizontal members can be provided at the edges of the

building panel and together with the vertical member form a peripheral frame for

the building panel. The foam is bonded to the horizontal and vertical stud members

using above ambient temperatures and pressures. Building panels can be coupled to

one another to construct a structure, such as a room, floor, level and roof, using

vertical members at the edges having an interlocking capabilities. One or more

building panels can be inserted into one or more tracks secured to a floor to hold the

one or more building panels in an upright position.

[0006] According to an embodiment of the present invention, a building

panel having structural integrity is provided. The building panel includes a

peripheral frame having a top horizontal stud member, a bottom horizontal stud

member, a left vertical stud member, and a right vertical stud member. A first end

portion of the top horizontal stud member joins to a first end portion of left vertical

stud member, a second end of the top horizontal stud member joins to a first end

portion of right vertical stud member, a first end portion of the bottom horizontal

stud member joins to a second end portion of left vertical stud member, and a

second end portion of the bottom horizontal stud member joins to a second end of

the right vertical stud member. A foam is formed at least within the peripheral

frame, wherein the foam is bonded to the peripheral frame. A first side of the foam

defines an exterior surface of the building panel, and a second side of the foam

defines an interior surface of the building panel. Mesh is provided within the foam.

[0007] In an embodiment of the present invention, the structural integrity of

the building panel is derived from the bonding of the foam to the peripheral frame.

[0008] In an embodiment of the present invention, the foam comprises a

thermoplastic material or a thermoset material.

[0009] In an embodiment of the present invention, the top horizontal stud

member, the bottom horizontal stud member, the right vertical stud member, and

the left vertical stud member are constructed from one of: metal, aluminum, wood,

and plastic.

[00010] In an embodiment of the present invention, the top horizontal stud

member, the bottom horizontal stud member, the right vertical stud member, and

the left vertical stud member are configured as one of: a convention stud, a c-shaped

stud, and an interlocking stud.

[00011] In an embodiment of the present invention, a first side of the foam

defines an exterior surface of the building panel and a second side of the foam

defines an interior surface of the building panel.

[00012] In an embodiment of the present invention, a fiber reinforced surface

layer is applied to the exterior surface of the building panel.

[00013] In an embodiment of the present invention, a fiber reinforced surface

layer is applied to the interior of the building panel.

[00014] In an embodiment of the present invention, the foam and the mesh

extends to the outer boundary of the peripheral frame.

[00015] In an embodiment of the present invention, ate least one of the right

vertical stud member, the left vertical stud member, top horizontal stud member,

and bottom horizontal stud member is an interlocking stud operable to interlock

with an interlocking stud of an adjacent structural component.

[00016] According to an embodiment of the present invention, an interlocking

stud to guide to edge of a first building panel into a receiving edge of another

building is provided.

[00017] In an embodiment of the present invention, a structural component

couples to the interlocking stud within the first side wall and second side wall.

[00018] In an embodiment of the present invention, the interlocking stud is

operable to interlock with another interlocking stud.

[00019] According to an embodiment of the present invention, an improved

modular building is provided. The building includes a first set of building panels

defining a perimeter of the modular building, wherein each of the building panels

include a peripheral frame having a top horizontal stud member, a bottom

horizontal stud member, a left vertical stud member, and a right vertical stud

member. A first end portion of the top horizontal stud member joins to a first end

portion of left vertical stud member. A second end of the top horizontal stud

member joins to a first end portion of right vertical stud member. A first end portion

of the bottom horizontal stud member joins to a second end portion of left vertical

stud member. A second end portion of the bottom horizontal stud member joins to

a second end of the right vertical stud member. A foam formed at least within the

peripheral frame is bonded to the peripheral frame. A first side of the foam defines

an exterior surface of the building panel, and a second side of the foam defines an

interior surface of the building panel. Each of the building panels configured with

an interlocking stud as the left vertical stud member and the right vertical stud

member for interlocking with an adjacent building panel configured with an

interlocking stud as the left vertical stud member and the right vertical stud

member. A covering is supported by, and secured to, the set of building panels.

[00020] In an embodiment of the present invention, the covering is constructed

from a second set of building panels.

[00021] In an embodiment of the present invention, tracks includes a base

portion, a first track sidewall, and a second track sidewall and is anchored to a

foundation of the modular building with a set of anchors including, but not limited

to, anchor bolts or other similar methods.

[00022] In an embodiment of the present invention, an anchor is inserted

through a hole receptive in the base portion of a track into the foundation and a top

portion of the anchor engages the base portion of the track and the base portion of

the track engages the foundation.

[00023] According to an embodiment of the present invention, A system for

securing a wall of a building to a foundation is provided. The system includes a

track including a base portion, a first track sidewall, and a second track sidewall and

an anchor each having a J-shape configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

[00024] The above described features and advantages of the present invention

will be more fully appreciated with reference to the detailed description and

appended figures in which:

[00025] Figs. IA- IB depict exemplary diagrams of a building panel having

structural integrity according to an embodiment of the present invention;

[00026] Fig. 1C depicts an exemplary top view of a c-shaped stud with foam

and mesh according to an embodiment of the present invention;

[00027] Fig. 2 depicts an exemplary diagram of a building panel with a

diagonal stud member having structural integrity according to an embodiment of the

present invention;

[00028] Fig. 3 depicts an exemplary diagram of a building panel with an inner

vertical stud member having structural integrity according to an embodiment of the

present invention;

[00029] Fig. 4 depicts an exemplary diagram of an anchor and track according

to an embodiment of the present invention;

[00030] Fig. 5 depicts an exemplary flow chart of a method for constructing a

structure using a set of building panels according to an embodiment of the present

invention; and

[00031] Fig. 6 depicts an exemplary flow chart of a method of fabricating the

building panel shown in Fig. 1.

DETAILED DESCRIPTION OF THE INVENTION

[00032] The present invention is now described more fully hereinafter with

reference to the accompanying drawings that show embodiments of the present

invention. The present invention, however, may be embodied in many different

forms and should not be construed as limited to embodiments set forth herein.

Appropriately, these embodiments are provided so that this disclosure will be

thorough and complete, and will fully convey the scope of the present invention.

[00033] According to an embodiment of the present invention, a building

panel having structural integrity, a method of fabricating the building panel having

structural integrity and method of constructing a building employing the building

panel are provided. The building panel is a one layer building panel that derives its

structural integrity from a foam forming the layer that bonds to horizontal and

vertical stud members. The vertical stud members can be provided at the edges of

the building panel. The horizontal stud members can be provided at the edges of

the building panel and together with the vertical stud member form a peripheral

frame for the building panel. The foam is bonded to the horizontal and vertical stud

members using temperatures and pressures above ambient. Building panels can be

coupled to one another to construct a structure, such as a room, floor, level and roof,

using vertical and horizontal stud members at the edges having an interlocking

capabilities. One or more building panels can be inserted into one or more tracks

secured to a floor to hold the one or more building panels in an upright position.

[00034] Exemplary diagrams of a building panel having structural integrity

according to an embodiment of the present invention are shown in Figs. 1A-1B. In

the embodiment of Fig. IA, building panel 100 includes a top horizontal stud

member 102, a bottom horizontal stud member 104, a right vertical stud member

106, a left vertical stud member 108, and a foam member 110. The building panel

of Fig. IA includes an exterior panel side 112, an interior panel side 114, and a

mesh member 116 positioned within foam member 110 as shown in Fig. IB. In the

Fig. IA embodiment of the present invention, the top horizontal stud member 102,

bottom horizontal stud member 104, right vertical stud member 106, and left

vertical stud member 108 can be constructed from one of metal, aluminum, wood

and plastic. In an embodiment of the present invention, a stud member, such as top

horizontal stud member 102, bottom horizontal stud member 104, right vertical stud

member 106, and/or left vertical stud member 108, can be configured as a

conventional stud, a c-shaped stud, an interlocking stud, or the like. In an

embodiment of the present invention, the foam member 110 forms around the c-

shaped stud members to provide increase structural integrity and mesh member 116

couples to c-shaped stud member as shown in Fig. 1C. In an embodiment of the

present invention, the mesh member 116 is provided within the foam member 110.

In an embodiment of the present invention, the mesh can span the extent of the

foam member 110 and couple to each of the top horizontal stud member 102,

bottom horizontal stud member 104, right vertical stud member 106, and left

vertical stud member 108. In an embodiment of the present invention, a set of mesh

members can be provided within the foam member 110 and extend from the top

horizontal stud member 102 to the bottom horizontal stud member 104. In an

embodiment of the present invention, a set of mesh members can be provided

within the foam member 110 and extend from the left vertical stud member 108 to

the right vertical stud member 106.

[00035] The mesh member 116 can be configured from materials including,

but not limited to, aluminum, steal, copper, and plastic. In an embodiment of the

present invention, the mesh size can be from 2 Mesh to 325 Mesh which means the

number of meshes per lineal inch of material. In an embodiment of the present

invention, the mesh size can be 5 Mesh to 300 Mesh. In an embodiment of the

present invention gauge of the mesh can be from 50 gauge to 10 gauge. In another

embodiment, the mesh has a gauge ranging from 40 to 10. In an embodiment of the

present invention, the mesh has a gauge ranging from 30 to 15.

[00036] In an embodiment of the present invention, a surface of foam member

110 can be provided with a fiber reinforced surface layer as shown in Fig. 1C. The

fiber can be made from any material that strengthens the impact level of the panel

member 100. The material can be, but is not limited to, Fiberglass, Aramid, Carbon

and Natural fibers. In an embodiment of the present invention, the weight per

square yard of the fiber can range from 12 oz. to 300 oz. In an embodiment of the

present invention, the weight per square yard of the fibber can range from 12 oz. to

100 oz. In an embodiment of the present invention, the weight per square yard of

the fiber can range from 75 oz. to 200 oz. In an embodiment of the present

invention, the weight per square yard of the fibber can range from 125 oz. to 300

oz. The orientation of the fibers with respect to the longitudinal axis of the panel

surface can be 0, +/-5, +/-10, +/-15, +/-30, +/-45, +/-60 and +/-90 degrees or any

angle in between. The fiber layers can be either stitch bonded or woven together to

form multiple ply cloths which are utilized in the production of the panels.

[00037] In the Fig. IA embodiment of the present invention, top horizontal

stud member 102 and bottom horizontal stud member 104 are axially aligned and

positioned at the upper and lower periphery of building panel 100 to form the top

and bottom of building panel 100. In an embodiment of the present invention, top

horizontal stud member 102 and bottom horizontal stud member 104 are axially

align and positioned at a predetermined distance from one another. In the Fig. IA

embodiment of the present invention, right vertical stud member 106 and left

vertical stud member 108 are axially aligned and positioned at the left and right

periphery of building panel 100 to form the left side and right side of building panel

100. In an embodiment of the present invention, left vertical stud member 108 and

right vertical stud member 106 are axially aligned and positioned at a predetermined

distance from one another. In an embodiment of the present invention, the vertical

stud members 106 and 108 extend the height of the building panel 100 and the

horizontal stud members 102 and 104 extend the length of the building panel 100.

In an embodiment of the present invention, the vertical stud members 106 and 108

of building panel 100 are configured to interlock with a vertical stud member of an

adjacent building panel 100 to form a wall or room. In an embodiment of the

present invention, the horizontal stud members 102 and 104 are configured to

interlock with the interlocking stud members of building panels used to form a

ceiling, roof, or floor of a structure. The building panel can be secured to a floor

member to hold the building panel in an upright position by methods including, but

not limited to, slots in the foundation or direct fixation with screws, welds or

adhesives.

[00038] In the Fig. IA embodiment of the present invention, the top horizontal

stud member 102, bottom horizontal stud member 104, right vertical stud member

106, and left vertical stud member 108 form a frame around panel member 110. In

the Fig. IA embodiment of the present invention, a first end portion of the top

horizontal stud member 102 squarely abuts a first end portion of left vertical stud

member 108. In the Fig. IA embodiment of the present invention, a second end of

the top horizontal stud member 102 squarely abuts a first end portion of right

vertical stud member 106. In the Fig. IA embodiment of the present invention, a

first end portion of the bottom horizontal stud member 104 squarely abuts a second

end portion of left vertical stud member 108. In the Fig. IA embodiment of the

present invention, a second end portion of the bottom horizontal stud member 104

squarely abuts a second end of right vertical stud member 106. In an embodiment

of the present invention, the members can be coupled, such as by screws, welding,

adhesive and bolts, at the points of abutment to further provide structural integrity.

[00039] In the Fig. IA embodiment of the present invention, panel member

110 extends and bonds to the inner side of each of the top horizontal stud member

102, bottom horizontal stud member 104, right vertical stud member 106, and left

vertical stud member 108. In the Fig. IA embodiment of the present invention, the

thickness of the panel member 110 is substantially the same as the width of the top

horizontal stud member 102, bottom horizontal stud member 104, right vertical stud

member 106, and left vertical stud member 108. The front side and back side of the

foam member 110 defines the exterior and interior of building panel 100. In an

embodiment of the present invention, building panel 100 conforms to chapter 26 of

the International building code for requirements including, but not limited to, flame

spread and smoke spread.

[00040] In an embodiment of the present invention, panel member 110 extends

to the outer side of each of the top horizontal stud member 102, bottom horizontal

stud member 104, right vertical stud member 106, and left vertical stud member

108 and bonds to the back, front, and inner sides of each of the top horizontal stud

member 102, bottom horizontal stud member 104, right vertical stud member 106,

and left vertical stud member 108. In an embodiment of the present invention, the

panel member 110 thickness extends beyond the width of each of the top horizontal

stud member 102, bottom horizontal stud member 104, right vertical stud member

106, and left vertical stud member 108. In an embodiment of the present invention,

the front side and back side of the foam member 110 defines the exterior and

interior of building panel 100 as well as the exterior and interior of a wall, roof, or

ceiling for a structure constructed with building panel 100.

[00041] An exemplary embodiment of the building panel 100 of Figs. IA - IB

is shown in Fig. 2 with a diagonal stud member. In the Fig 2 embodiment of the

present invention, diagonal stud member 202 can be constructed from one of metal,

aluminum, wood and plastic. In the Fig. 2 embodiment of the present invention, a

first end portion of the diagonal stud member 202 abuts to a second end portion of

the top horizontal stud member 102 and a first end portion of right vertical stud

member 106. In the Fig. 2 embodiment of the present invention, a second end

portion of the diagonal stud member 202 abuts a first end portion of the bottom

horizontal stud member 104 squarely and second end portion of left vertical stud

member 108. In the Fig. 2 embodiment of the present invention, panel member 110

extends and bonds to the inner side of each of the top horizontal stud member 102,

bottom horizontal stud member 104, right vertical stud member 106, and left

vertical stud member 108 as well as the right and left side of diagonal stud member

202. In an embodiment of the present invention, the members can be coupled at the

points of abutment to further provide structural integrity.

[00042] An exemplary embodiment of the building panel 100 of Figs. IA - IB

is shown in Fig. 3 with an inner vertical stud member. In the Fig. 3 embodiment of

the present invention, an inner vertical stud member 302 can be constructed from

one of metal, aluminum, wood and plastic. In the Fig. 3 embodiment of the present

invention, a fist end portion of an inner vertical stud member 302 squarely abuts the

top horizontal stud member 102 and a second end of the inner vertical stud member

302 squarely abut the bottom horizontal stud member 104. In the Fig. 3

embodiment of the present invention, panel member 110 extends and bonds to the

inner side of each of the top horizontal stud member 102, bottom horizontal stud

member 104, right vertical stud member 106, and left vertical stud member 108 as

well as the right and left side of inner vertical stud member 106. In an embodiment

of the present invention, the members can be coupled at the points of abutment to

further provide structural integrity. In an embodiment of the present invention,

inner stud members can be configured to define openings for doors, windows, and

the like.

[00043] An exemplary side view of an anchor and track is shown in Fig. 4. In

the Fig. 4 embodiment of the present invention, the track 400 has a C-shaped

configuration having a base and two sidewalls projecting upward from the base,

which can be secured to a floor at the side of base opposite the sidewalls using one

or more anchors. In an embodiment of the present invention, the track 400 can be

used to hold one or more wall structures, such as a building panel 100, in an upright

position between the sidewalls. The track 400 can be constructed from one of

metal, aluminum, and the like. In an embodiment of the present invention, the track

can be secured to a floor using an anchor 402 including, but not limited to, one or a

combination of screws, bolts, welds, anchors, adhesive, and the like. The anchor

402 can be constructed from one of metal, steel, and the like. In an embodiment of

the present invention, the floor is pre-dried concrete and the base of the track 400

meets with a pre-dried concrete floor. Once the concrete dries, the track 400 and

anchor are securely fastened to the concrete floor.

[00044] An exemplary flow chart of a method of constructing a structure using

the building panels, anchor and track, and interlocking stud member is shown in

Fig. 5. The type of structure includes, but are not limited to, a wall, roof, room,

home, commercial building, strip mall, cold storage facility, and apartment

building. The method begins with step 500. In step 500, a set of tracks is

positioned in a configuration to define the outer boundaries of a building. In step,

502, anchors are inserted through holes in the tracks and into the floor that the

tracks sit on. In an embodiment of the present invention, the floor is concrete. In

step 504, the walls of the structure are constructed. In the Fig. 5 embodiment of the

present invention, construction of a wall includes, inserting a set of building panels

within the sidewalls of the track and interlocking the interlocking stud members of

adjacent building panels. To inserting a building panel within the sidewalls of the

track, the building panel can be lifted over the sidewalls of the track. Interlocking

the interlocking stud of the building panel to the interlocking stud of an adjacent

building panel is performed prior to inserting the building panel into the track. The

interlocking of interlocking studs and insertion of interlocked building panels into

the track secures the interlocked building panels to one another in an upright

position. A ceiling constructed from the building panels can be secured to a wall

constructed of the ceiling panels employing an eave lock, wherein the eave lock has

a base portion and a pair of sidewall, each sidewall being angled away from the

base portion.

[00045] An exemplary flow chart of a method of fabricating the building panel

of Fig. 1 is shown in Fig. 6. The method begins in step 600. In step 600, a

peripheral frame of stud members is placed in a mold press. In an embodiment of

the present invention, the mold press includes an enclosure having a top panel,

sidewalls and a bottom panel. In an embodiment of the present invention, a mesh

is coupled to the peripheral frame. In an embodiment of the present invention, a

mesh is suspended within the peripheral frame. In an embodiment of the present

invention, dry fiber is laid on the bottom panel and/or provided on the top panel of

the mold press.

[00046] In step 602, the top panel is placed on, and secured to the sidewalls.

In an embodiment of the present invention, the top panel is secured to the sidewalls

with sufficient strength to sustain pressures achieved by the mold press. In one

embodiment, the studs and/or mesh can be surface treated for improved bonding.

Surface treatment can be effected by any of the several techniques known in the art,

such as corona discharge, plasma treatment, ozone treatment, sand blasting, brush

tumbling, and the like. Preferably, surface treatment is effected by grinding with an

abrasive wheel. As will be appreciated by those of ordinary skill in the art, the

effect of the surface treatment can vary based on the type of material used to

fabricate the stud and/or mesh. For example, a metal stud can be subjected to sand

blasting in order to increase the adhesion between the metal stud and the foam

material.

[00047] In an alternate embodiment, a metal stud can be pretreated with a

plasma thermal spray coating thus taking advantage of the ability of plasma

technology to excite gas atoms and molecules into transient and nonequilibrium

conditions. An enclosed vacuum chamber can be used to excite the gas molecules

by subjecting the gas mixture to an electrified field of radio frequency (rf) energy.

In the alternative, the plasma technology can be performed under atmospheric

pressure and ambient temperature, without the use of vacuum equipment. The

oxygen functionalities created on the surfaces are chemically reactive and

permanent and allow the foam material to form a covalent bond to the modified

surface.

[00048] In step 604, a foam is injected and distributed consistently into the

mold press. In an embodiment of the present invention, the foam is injected within,

and bonded to, the peripheral frame. In an embodiment of the present invention, the

foam is injected within, over, and bonded to, the frame. In an embodiment of the

present invention, the foam has a thickness substantial equivalent to the thickness of

the stud members of the peripheral frame. In an embodiment of the present

invention, the foam has a thickness to substantially cover the stud members of the

peripheral frame.

[00049] In the Fig. 6 embodiment of the present invention, the press can be

maintained above-ambient pressure, where the pressure is directly related to the

density of the foam. In an embodiment of the present invention, the density of the

foam can be based on the specific application that the building panel is going to be

used. Any suitable temperature and pressure can be provided that allows the

reaction to proceed. For example, the temperature may range from about 32 ⁰ F to

about 180 ⁰ F. In one embodiment, the reaction temperature is about 75 ⁰ F to about

17O ⁰ F. In another embodiment, the reaction occurs at a temperature of about 75 ⁰ F

to about 15O ⁰ F. In yet another embodiment, the reaction occurs at a temperature of

about 80 ⁰ F to about 85°F. The pressure may range from about 1 psi to about 15 psi.

In one embodiment of the present invention, the pressure is about 3 psi to about 10

psi. In another embodiment of the present invention, the reaction occurs under a

pressure of about 5 psi to about 7 psi.

[00050] The foam can be any suitable foam material that is capable of being

injected and distributed consistently within the peripheral frame. For example, the

foam material may be a thermoset material or a thermoplastic material. The foam

may include, but is not limited to, polystyrene, polyurethane, polyurea,

polyisocyanurate, and the like. In one embodiment, the material is a molded

expanded polystyrene foam. In another embodiment, the material is an extruded

expanded polystyrene foam.

[00051] In still another embodiment, polyurethane foam is used. The

polyurethane foam may be a single-component polyurethane, where the main

components (isocyanate and a hydroxy-terminated component) are stored together

as a blended mix, accompanied by a blowing agent in liquid form, and catalyzed to

cure when exposed to moisture in the air. On release from their pressurized

container, the two main components react chemically, and the heat from this

reaction causes the blowing agent to convert into a gas and expand to form the

cellular structure of the foam. When the reaction is complete, the gas is trapped

within the material. In two-component polyurethane, the same two main

ingredients and appropriate catalysts are kept apart until application. The chemical

reaction when they are combined is much faster than with one-component foam.

Curing is chemical, requires no air or moisture, and is independent of the

surrounding environment. As an alternative, polyiscyanurate foam may be used for

improved fire-resistance and higher R-values as compared to polyurethane foam.

[00052] In yet another embodiment, the foam material includes polyurea

linkages and may be prepared by reacting an isocyanate with an amine-terminated

component. Whether the foam includes urethane or urethane linkages, the foam

may be the result of a one-shot method or a prepolymer method. Those of ordinary

skill in the art will appreciate that the different methods have advantages and

disadvantages depending on the application.

[00053] Any isocyanate available to one of ordinary skill in the art is suitable

for use according to the invention. Isocyanates for use with the present invention

include aliphatic, cycloaliphatic, araliphatic, aromatic, any derivatives thereof, and

combinations of these compounds having two or more isocyanate (NCO) groups per

molecule. Suitable isocyanate-containing components include diisocyanates having the generic structure: O=C=N-R-N=C=O, where R is preferably a cyclic, aromatic,

or linear or branched hydrocarbon moiety containing from about 1 to about 20

carbon atoms.

[00054] Suitable hydroxy-terminated components include, but are not limited

to, polyols including polyether polyols, polycaprolactone polyols, polyester polyols,

polycarbonate polyols, hydrocarbon polyols, and mixtures thereof. Both saturated

and unsaturated polyols are suitable for use with the present invention. Non-

limiting examples of amine-terminated compounds for use with the present

invention include amine-terminated hydrocarbons, amine-terminated polyethers,

amine-terminated polyesters, amine-terminated polycarbonates, amine-terminated

polycaprolactones, and mixtures thereof. The amine-terminated segments may be

in the form of a primary amine (NH ₂ ) or a secondary amine (NHR).

[00055] If the prepolymer method is used to form a polyurethane or polyurea-

1 based material, the curing agent may include hydroxy-terminated curing agents,

amine-terminated curing agents, and mixtures thereof. For example, any of the

hydroxy-terminated compounds or amine-terminated compounds discussed above

are also suitable for use as a curative.

[00056] As known to those of ordinary skill in the art, aliphatic or saturated

components, i.e., components that do not include C=C or aromatic rings, produce

foam materials that are less susceptible to ultraviolet light. As such, in one

embodiment (when applicable), the foam includes only aliphatic components to

result in a non-yellowing product. This embodiment is especially useful when the

panels are intended to be left unpainted once installed.

[00057] Foaming of the material of the invention may occur through the

addition of at least one physical or chemical blowing or foaming agent. Suitable

blowing or foaming agents include, but are not limited to, organic blowing agents,

such as azobisformamide; azobisisobutyronitrile; diazoaminobenzene;

N,N-dimethyl-N,N-dinitrosoterephthalamide;

N,N-dinitrosopentamethylene-tetramine; benzenesulfonyl-hydrazide; benzene- 1 ,3-

disulfonyl hydrazide; diphenylsulfon-3-3, disulfonyl hydrazide; 4,4'-oxybis benzene

sulfonyl hydrazide; p-toluene sulfonyl semicarbizide; barium azodicarboxylate;

butylamine nitrile; nitroureas; trihydrazino triazine; phenyl-methyl-uranthan;

p-sulfonhydrazide; peroxides; and inorganic blowing agents such as ammonium bicarbonate and sodium bicarbonate.

[00058] In another embodiment, the material is foamed forcing a pressurized

gas, such as nitrogen or carbon dioxide, into the polymerizing mixture. In another

embodiment, the material is foamed by blending microspheres with the composition

either during or before the molding process. Polymeric, ceramic, metal, and glass

microspheres are useful in the invention, and may be solid or hollow and filled or

unfilled.

[00059] The foamed material may be closed-cell or open-cell, however, as

known to those of ordinary skill in the art, a closed-cell foam material forms a

hydrophobic top skin. As such, if the material of the invention is initially an open-

cell foam, a subsequent sealant is preferred to add hydrophobicity to the cured

material.

[00060] In step 606, the top panel of the mold press is removed. In step 708,

the building panel is removed from the mold press.

[00061] While specific embodiments of the present invention have been

illustrated and described, it will be understood by those having ordinary skill in the

art that changes can be made to those embodiments without departing from the

spirit and scope of the invention.