Composite building components

Abstract

A structural insulated panel having a core ( 40 ) of expanded polystyrene sandwiched between, and bonded to, two facings ( 52 ). The facings are attached to faces of the core formed by moulding. Preferably the core is an expanded polymer moulding and the preferred polymer is polystyrene. The panel is useful as a building component.

1 . A structural insulated panel having a core of expanded polystyrene sandwiched between, and bonded to, two facings, the facings being attached to faces of the core formed by moulding.  
   
   
       2 . A panel as claimed in  claim 1  wherein the core is an expanded polystyrene moulding.  
   
   
       3 . A panel as claimed in  claim 2  wherein the core is formed by expansion of polystyrene cells in a mould in such that any variations in density are minimal.  
   
   
       4 . A panel as claimed in any preceding claim wherein the expanded polystyrene is produced by pre-expanding polystyrene, maturing the pre-expanded polystyrene and then expanding the pre-expanded polystyrene and then expanding the pre-expanded matured polystyrene in steam.  
   
   
       5 . A panel as claimed in any preceding claim wherein the panel dimensions are 1.2 metres wide, 0.2 metres thick and 2.4 metres high/long.  
   
   
       6 . A panel as claimed in any preceding claim wherein the facings are made from cementitious board, plywood, gypsum/textile composite board or OGB.  
   
   
       7 . A panel as claimed in any preceding claim wherein the core comprises two mirror image halves.  
   
   
       8 . A panel as claimed in  claim 7  wherein each mirror image half of the core is provided with male/female location means for engagement of the two halves.  
   
   
       9 . A panel as claimed in any preceding claim wherein the core includes at least one passageway.  
   
   
       10 . A panel as claimed in  claim 9  wherein there is a matrix of passageways positioned such that each passageway will align with, and be capable of connection to, a passageway of an adjacent such panel.  
   
   
       11 . A panel as claimed in any preceding claim wherein an organic non-solvent, moisture controlled penetrative adhesive or glue is employed for bonding the parts of the panel together.  
   
   
       12 . A panel as claimed in any preceding claim including recesses along the edges of oppositely facing surfaces of the core for receiving joining elements for connecting the panel to another such panel.  
   
   
       13 . Use of an individual moulding of expanded polystyrene as a core in a structural insulated panel in which the core is sandwiched between, and bonded to, two facings.  
   
   
       14 . A method of manufacturing a structural insulated panel comprising forming an expanded polystyrene core with at least two opposite faces produced by moulding and bonding facings to the two moulded faces.  
   
   
       15 . A method as claimed in any preceding claim wherein the step of forming an expanded polystyrene core comprises pre-expanding polystyrene beads by heating the beads and providing steam thereto, cooling and drying the pre-expanded beads, maturing the pre-expanded beads and then further expanding the pre-expanded and matured beads with steam in a mould.  
   
   
       16 . A method as claimed in  claim 15  wherein the mould used for further expansion of the pre-expanded and matured beads comprises a two part mould defining a mould cavity, each part being connected to a steam source, wherein the surfaces of the mould cavity are provided with a multiplicity of steam injection points.  
   
   
       17 . A method as claimed in either  claim 15  or  claim 16  wherein the mould is an hermaphrodite mould.  
   
   
       18 . A method as claimed in  claim 17  wherein the mould is shaped to provide each half of the core with male/female location means.  
   
   
       19 . A method as claimed in any one of  claims 15  to  18  wherein the mould is shaped to form recesses along the edges of oppositely facing surfaces of the core.  
   
   
       20 . A method as claimed in any one of  claims 15  to  19  wherein the mould is shaped to form at least one passageway in the core.  
   
   
       21 . A method as claimed in any one of  claims 14  to  20  wherein the bonding of parts of the panel is carried out with an organic non-solvent, moisture controlled penetrative adhesive or glue.  
   
   
       22 . A method of constructing a building comprising using a panel as claimed in any one of  claims 1  to  12 .