Foamed-in-place double-skin building construction panel

Claim 2

A building construction panel comprising an outer facing sheet, an inner facing sheet spaced from said outer facing sheet, and a foamed-in-place core filling the space between and bonding said outer facing sheet to said inner facing sheet; each said facing sheet including: a web having first and second longitudinal edges; spaced-apart, generally parallel, longitudinal ribs projecting from said web into said foamed-in-place core, each of said ribs of each facing sheet includIng a base portion confronting the web of the other said facing sheet and sidewalls connecting said base portion to said web, said sidewalls of each of said ribs converging toward said web and having a maximum separation presented within said foamed-in-place core, whereby said ribs provide plural positive mechanical connections between each said facing sheet and said foamed-in-place core; the base portions of said ribs of each said facing sheet being at a level between (a) the web of the other facing sheet and (b) a plane containing surfaces of the base portions of said ribs of the other facing sheet; and means provided by each said facing sheet for connecting the said first and second longitudinal edges thereof to corresponding longitudinal edges of adjacent ones of the building construction panels.

Claim 3

A building construction panel comprising an outer facing sheet, an inner facing sheet spaced from said outer facing sheet, and a foamed-in-place core filling the space between and bonding said outer facing sheet to said inner facing sheet; each said facing sheet including: a web having first and second longitudinal edges; spaced-apart, generally parallel, longitudinal ribs projecting from said web into said foamed-in-place core, said ribs of each facing sheet being laterally offset from the ribs of the other facing sheet, each of said ribs of each facing sheet including a base portion confronting the web of the other said facing sheet and sidewalls connecting said base portion to said web, said sidewalls of each of said ribs converging toward said web and having a maximum separation presented within said foamed-in-place core, whereby said ribs provide plural positive mechanical connection between each said facing sheet and said foamed-in-place core; the said first longitudinal edge of each facing sheet being laterally offset from the said second longitudinal edge of the other facing sheet whereby the said outer facing sheet is entirely spaced-apart from the said inner facing sheet; and means provided by each said facing sheet for connecting the said first and second longitudinal edges thereof to corresponding longitudinal edges of adjacent ones of the building construction panels.

Claim 4

A building construction panel comprising an outer facing sheet, an inner facing sheet spaced from said outer facing sheet, and a foamed-in-place core filling the space between and bonding said outer facing sheet to said inner facing sheet; each said facing sheet including: a web having first and second longitudinal edges; spaced-apart, generally parallel, longitudinal ribs projecting from said web into said foamed-in-place core, said ribs of each facing sheet being laterally offset from the ribs of the other facing sheet, each of said ribs of each facing sheet including a base portion confronting the web of the other said facing sheet and sidewalls connecting said base portion to said web, said sidewalls of each of said ribs converging toward said web and having a maximum separation presented within said foamed-in-place core, whereby said ribs provide plural positive mechanical connection between each said facing sheet and said foamed-in-place core; the said first longitudinal edge of each facing sheet being laterally offset from the said second longitudinal edge of the other facing sheet whereby the said outer facing sheet is entirely spaced-apart from the said inner facing sheet; and means provided by each said facing sheet for connecting the said first and second longitudinal edges thereof to corresponding longitudinal edges of adjacent ones of the building construction panels.

Claim 5

The building construction panel of claim 2 wherein each of said ribs is generally trapozoidal in cross section.

Claim 6

The building construction panel of claim 2 wherein each of said ribs is generally arcuate in cross section.

Claim 7

The building construction panel of claim 2 wherein each of said ribs has a polygonal configuration.

Claim 8

The building construction panel of claim 2 wherein said means comprises: a first partial rib formed along said first longitudinal edge; and a second partial rib formed along said second longitudinal edge; said building construction panel adapted to be engaged side by side with others of said building construction panel, with the said first partial rib of each facing sheet engaged with the said second partial rib of a corresponding facing sheet of an abutting building construction panel whereby the outer facing sheets are mechanically engaged with one another.

Claim 9

A building wall structure comprising a plurality of building construction panels according to claim 2 erected in side-by-side overlapped relation; said means comprising a first partial rib formed along the said first longitudinal edge of each said facing sheet, and a second partial rib formed along the said second longitudinal edge of each said facing sheet; the said first partial rib of each facing sheet interfitting the second partial rib of a corresponding facing sheet of an abutting building construction panel; and fastener means for securing the said first partial rib of each facing sheet to the second partial rib of said corresponding facing sheet of an abutting building construction panel.

Claim 10

The building wall structure of claim 7 wherein said first partial rib of each facing sheet includes a first base portion; saId second partial rib of each facing sheet includes a second base portion engaged with the said first base portion; and said fastener means extends through the said first base portion and the said second portion into said foamed-in-place core.