Composite building module

Claim 1

Process for making a monolithic-like, insulated composite building module having a fiber-reinforced, continuous and integral cement shell encasing a rigid foam core which comprises: (a) providing a mold having a bottom and side walls; (b) successively applying individual lengths of fibers and wet cement to the bottom of the mold, said fibers being applied by chopping rolls of continuous fiber and spraying the chopped fibers into the mold; (c) substantially uniformly distributing the chopped fibers in a random fashion throughout the entire volume of the wet cement applied in step (b) to form a layer of wet cement and fibers in the bottom of the mold; (d) placing a rigid foam core member on said layer of wet cement and fibers, said core member having a peripheral shape smaller than the mold interior leaving a free space between the core member and the mold side walls, said core member having a thickness less than the height of the mold side walls; (e) successively applying individual lengths of fibers and wet cement to the top of the core member and the free space between the member and the mold side walls, said fibers being applied by chopping rolls of continuous fiber and spraying the chopped fibers into the mold; (f) substantially uniformly distributing the chopped fibers in a random fashion throughout the entire volume of the cement applied in step (e) thereby encasing said core with a wet cement shell that is continuous, integral around the core and fiber reinforced; and (g) curing said wet cement shell and removing the thus formed module from the mold.