Building panel core

Claim 1

A structural panel core for forming a wall or the like, the structural panel core including an interior lattice structure, an exterior lattice structure, and a substantially continuous filler layer between the interior and exterior lattice structures, the wall further including an inner cementitious layer adjacent the filler layer and enclosing the interior lattice structure and an outer cementitious layer adjacent the filler layer and enclosing the exterior lattice structure, the structural panel core further comprising: the interior lattice structure including a first plurality of substantially parallel elongate reinforcing members and a second plurality of substantially parallel elongate reinforcing members each fixedly interconnected to the first plurality of reinforcing members, the first and second reinforcing members defining an interior plane; the exterior lattice structure including a third plurality of substantially parallel elongate reinforcing and a fourth plurality of substantially parallel elongate reinforcing members each fixedly interconnected to the third plurality of reinforcing members, the third and fourth reinforcing members defining an exterior plane; a plurality of structurally separate elongate wire segments each having a straight line configuration between opposing terminal ends of each wire segment and passing through the filler layer for fixedly interconnecting the interior lattice structure with the exterior lattice structure, each of the wire segments fixedly secured adjacent a respective opposing terminal end at a compound inclination to each of the interior and exterior lattice structure and at a position spaced from other of the plurality of wire segments, such that each wire segment is structurally supported by the interior and exterior lattice structures and independent of other of the plurality of wire segments, and such that an included angle is formed between each wire segment and any plane perpendicular to either the interior plane or the exterior planes; and each of the plurality of wire segments forming a side of an imaginary pyramid having remaining sides formed by other of the plurality of wire segments, the wire segments being fixedly secured to the interior and exterior lattice structure such that an apex of the imaginary pyramid is spaced opposite one of the lattice structures with respect to the other of the lattice structures.

Claim 16

A method of forming a light-weight structural panel core for a wall or the like, comprising: forming an interior lattice structure including a first plurality of substantially parallel elongate reinforcing members and a second plurality of substantially parallel elongate reinforcing members each interconnected to the first plurality of reinforcing members, the first and second plurality of reinforcing members defining an interior plane; forming an exterior lattice structure including a third plurality of substantially parallel elongate members and a fourth plurality of substantially parallel elongate reinforcing members each fixedly connected to the third plurality of reinforcing members, the third and fourth plurality of reinforcing members defining an exterior plane substantially parallel to the interior plane; positioning a substantially continuous filler layer between the interior and exterior lattice structures; passing each of a plurality of structurally separate elongate connecting members having a straight line configuration between opposing terminal ends of each wire segment through a filler layer at a preselected compound inclination to each of the interior and exterior lattice structures, such that an inclined angle is formed between each connecting member and any plane perpendicular to either the interior or exterior planes and each of the plurality of connecting members forms a side of an imaginary pyramid with an apex of the imaginary pyramids spaced opposite one of the lattice structures with respect to the other of the lattice structures; and fixedly connecting an opposing terminal end of each of the connecting members to the interior and exterior lattice structures, respectively, at a position spaced from other of the plurality of wire segments, such that each wire segment is structurally supported by the interior and exterior lattice structures and independent of the other of the plurality of wire segments.

Claim 17

A method of forming a light-weight structural panel core for a wall or the like, comprising: forming an interior lattice structure including a first plurality of substantially parallel elongate reinforcing members and a second plurality of substantially parallel elongate reinforcing members each interconnected to the first plurality of reinforcing members, the first and second plurality of reinforcing members defining an interior plane; forming an exterior lattice structure including a third plurality of substantially parallel elongate members and a fourth plurality of substantially parallel elongate reinforcing members each fixedly connected to the third plurality of reinforcing members, the third and fourth plurality of reinforcing members defining an exterior plane substantially parallel to the interior plane; positioning a substantially continuous filler layer between the interior and exterior lattice structures; passing each of a plurality of structurally separate elongate connecting members having a straight line configuration between opposing terminal ends of each wire segment through a filler layer at a preselected compound inclination to each of the interior and exterior lattice structures, such that an inclined angle is formed between each connecting member and any plane perpendicular to either the interior or exterior planes and each of the plurality of connecting members forms a side of an imaginary pyramid with an apex of the imaginary pyramids spaced opposite one of the lattice structures with respect to the other of the lattice structures; and fixedly connecting an opposing terminal end of each of the connecting members to the interior and exterior lattice structures, respectively, at a position spaced from other of the plurality of wire segments, such that each wire segment is structurally supported by the interior and exterior lattice structures and independent of the other of the plurality of wire segments.