Building panel

Abstract

The present disclosure relates to building panels, structures comprising building panels, and methods of manufacturing building panels. In a representative embodiment, a building panel comprises a fiber-reinforced polymer layer and an insulative layer disposed adjacent the fiber-reinforced polymer layer. The building panel can further comprise a rigid planar member disposed adjacent the insulative layer such that the insulative layer is located between the fiber-reinforced polymer layer and the rigid planar member. The building panel can further comprise one or more fiber-reinforced polymer connectors extending through the insulative layer between the fiber-reinforced polymer layer and the rigid planar member.

1 . A building panel, comprising:
 a fiber-reinforced polymer layer;   an insulative layer disposed adjacent the fiber-reinforced polymer layer;   a rigid planar member disposed adjacent the insulative layer such that the insulative layer is located between the fiber-reinforced polymer layer and the rigid planar member; and   one or more fiber-reinforced polymer connectors extending through the insulative layer between the fiber-reinforced polymer layer and the rigid planar member.   
     
     
         2 . The building panel according to  claim 1 , further comprising a concrete panel. 
     
     
         3 . The building panel of  claim 2 , wherein the concrete panel is disposed between the fiber-reinforced polymer layer and the insulative layer. 
     
     
         4 . The building panel of  claim 3 , wherein:
 the fiber-reinforced polymer layer is a first fiber-reinforced polymer layer; and   the rigid planar member is a second fiber-reinforced polymer layer.   
     
     
         5 . The building panel of  claim 3 , wherein the one or more-fiber-reinforced polymer connectors are compositely adhered to the concrete panel. 
     
     
         6 . The building panel of  claim 3 , wherein the concrete panel has a thickness of from about 0.5 inch to about twelve inches. 
     
     
         7 . The building panel of  claim 3 , wherein:
 the concrete panel is a first concrete panel; and   the rigid planar member is a second concrete panel.   
     
     
         8 . The building panel of  claim 7 , wherein:
 the fiber-reinforced polymer layer is a first fiber-reinforced polymer layer; and   the building panel further comprises a second fiber-reinforced polymer layer located adjacent the second concrete panel such that the second concrete panel is between the insulative layer and the second fiber-reinforced polymer layer.   
     
     
         9 . The building panel of  claim 1 , wherein the one or more fiber-reinforced polymer connectors are compositely adhered to the fiber-reinforced polymer layer and the rigid planar member. 
     
     
         10 . The building panel of  claim 1 , wherein the one or more fiber-reinforced polymer connectors are compositely adhered to the insulative layer. 
     
     
         11 . The building panel of  claim 1 , wherein the one or more connectors comprise a plurality of angled portions separated by alternating peaks and valleys. 
     
     
         12 . The building panel of  claim 1 , wherein the fiber-reinforced polymer layer includes fibers selected from carbon fibers, glass fibers, aramid fibers, or combinations thereof. 
     
     
         13 . The building panel of  claim 1 , wherein the insulative layer comprises at least one polymer selected from a polystyrene, an aliphatic polymer, a polyisocyanurate, or a polyurethane, or combinations thereof. 
     
     
         14 . The building panel of  claim 1 , wherein the insulative layer has a thickness of from about two inches to about twelve inches. 
     
     
         15 . The building panel of  claim 1 , wherein the building panel comprises a first building panel and a second building panel, the insulative layer of the first building panel being configured to partially overlap the rigid planar member of the second building panel. 
     
     
         16 . The building panel of  claim 1 , wherein the one or more fiber-reinforced polymer connectors comprise one or more elongate members having a plurality of projections extending from the elongate members. 
     
     
         17 . The building panel of  claim 16 , wherein the projections comprise one or more holes. 
     
     
         18 . A method of making a building panel, comprising:
 coupling one or more connectors to a rigid planar member;   installing an insulative layer adjacent the rigid planar member, the one or more connectors being configured to extend through the insulative layer; and   coupling a fiber-reinforced polymer layer to the one or more connectors such that the insulative layer is located between the rigid planar member and the fiber-reinforced polymer layer.   
     
     
         19 . The method of  claim 18  wherein, prior to coupling the fiber-reinforced polymer layer to the one or more connectors, the method further comprises casting a concrete panel on top of the insulative layer. 
     
     
         20 . The method of  claim 19 , wherein coupling the fiber-reinforced polymer layer further comprises coupling the fiber-reinforced polymer layer to the concrete panel and the one or more connectors. 
     
     
         21 . The method of  claim 19 , further comprising applying a layer of polymer concrete to the fiber-reinforced polymer layer prior to coupling the fiber-reinforced polymer layer to the concrete panel. 
     
     
         22 . The method of  claim 19 , wherein:
 the concrete panel is a first concrete panel; and   the rigid planar member is a second concrete panel.   
     
     
         23 . The method of  claim 22 , further comprising coupling a second fiber-reinforced polymer layer to the second concrete panel. 
     
     
         24 . The method of  claim 19 , wherein:
 the fiber-reinforced polymer layer is a first fiber-reinforced polymer layer; and   the rigid planar member is a second fiber-reinforced polymer layer.   
     
     
         25 . The method of  claim 18 , wherein installing the insulative layer further comprises pouring foam onto the rigid planar member, the foam comprising at least one of a polystyrene, an aliphatic polymer, a polyisocyanurate, a polyurethane, or a combination thereof. 
     
     
         26 . A structure including a building panel according to  claim 1 . 
     
     
         27 . The structure of  claim 26 , wherein the building panel further comprises a concrete panel located between the fiber-reinforced polymer layer and the insulative layer. 
     
     
         28 . The structure of  claim 27 , wherein the rigid planar member comprises a second fiber-reinforced polymer layer. 
     
     
         29 . The structure of  claim 27 , wherein the rigid planar member comprises a second concrete panel. 
     
     
         30 . The structure of  claim 26 , wherein the building panel is configured as a roof of the structure. 
     
     
         31 . The structure of  claim 26 , wherein the building panel is configured as a floor of the structure. 
     
     
         32 . A method, comprising:
 providing a building panel according to  claim 1 ; and   building a structure comprising the building panel.