Insulated wall panel

Abstract

The invention is an insulated wall panel system having structural elements that may be used as an exterior facade to a building. The insulated wall panel system provides a finished exterior surface, a structural component, and an insulation factor. The wall panel system may be used in new construction or in existing buildings. The wall panel system has an insulation layer, a middle cement layer, and an outer veneer layer. The outer veneer layer may include brick, stone, tile, or other material as a finished surface. The insulated wall panels may be attached directly to the studs or other structural element of a building.

We claim: 
     
         1 . A wall panel comprising:
 a middle layer having a first and a second side; and   an inner insulation layer, comprising a two part rigid urethane pour foam having a first side chemically bonded to the second side of the middle layer;   wherein the wall panel is characterized by a lack of any additional sagging prevention layer positioned between the inner insulation layer and a fixed structural building component.   
     
     
         2 . The wall panel of  claim 1  wherein the chemical bond between the first side of the inner insulation layer and the second side of the middle layer is formed during a pour by the reaction between each one of the parts of the two part rigid urethane pour foam. 
     
     
         3 . The wall panel of  claim 1  wherein the middle layer is made from glass reinforced cement. 
     
     
         4 . The wall panel of  claim 1  wherein the middle layer is made from an extruded and pressed board. 
     
     
         5 . The wall panel of  claim 1  wherein the middle layer is poured, press-molded, extruded, vibration cast, sprayed, and/or lip formed. 
     
     
         6 . The wall panel of  claim 1  wherein in a plurality of wall panels are attached to a building structure using an attachment selected from the group consisting of: screws, nails, bolts, welds, construction adhesive, rivets, and clasps. 
     
     
         7 . The wall panel of  claim 1  wherein one or more attachment points are positioned between the second side of the middle layer and the first side of the inner insulation layer.