Systems and methods for sealing a prefabricated panel

Abstract

Example embodiments of the described technology provide a prefabricated building panel. The prefabricated building panel may comprise an insulative core having first and second opposing faces. The prefabricated building panel may also comprise a cementitious layer covering one of the first and second opposing faces of the insulative core. The prefabricated building panel may also comprise a first interface between the insulative core and the cementitious layer. A sealing cap extending longitudinally along at least a portion of one edge surface of the panel may seal the interface.

What is claimed is: 
     
         1 . A prefabricated building panel, the panel comprising:
 an insulative core having first and second opposing faces;   a first cementitious layer covering the first face of the insulative core;   a first interface formed between the first cementitious layer and the insulative core; and   a sealing cap extending longitudinally along at least a portion of an edge surface of the panel, the sealing cap at least partially sealing the first interface.   
     
     
         2 . The panel of  claim 1  wherein the sealing cap comprises a membrane. 
     
     
         3 . The panel of  claim 2  wherein the membrane comprises a waterproof membrane. 
     
     
         4 . The panel of  claim 3  wherein the waterproof membrane is breathable. 
     
     
         5 . The panel of  claim 2  wherein the membrane comprises an upper and a lower surface, the lower surface of the membrane in contact with the edge surface of the panel and wherein the lower surface of the membrane comprises an adhesive. 
     
     
         6 . The panel of  claim 2  wherein the membrane has a thickness of less than 5 mm. 
     
     
         7 . The panel of  claim 2  wherein the membrane wraps over at least one face of the insulative core. 
     
     
         8 . The panel of  claim 7  wherein the membrane wraps over the at least one face of the insulative core by an amount in the range between 0.25 inches and 2 inches. 
     
     
         9 . The panel of  claim 7  further comprising a sealant, the sealant sealing an interface formed between the membrane and the first cementitious layer. 
     
     
         10 . The panel of  claim 9  wherein the sealant comprises caulking. 
     
     
         11 . The panel of  claim 1  wherein the sealing cap comprises a liquid seal, the liquid seal covalently bonded to one or both of the insulative core and the first cementitious layer. 
     
     
         12 . The panel of  claim 1  wherein the sealing cap comprises a fiberglass cap. 
     
     
         13 . The panel of  claim 1  further comprising:
 a second cementitious layer covering the second face of the insulative core; and 
 a second interface between the second cementitious layer and the insulative core; 
 wherein the sealing cap at least partially seals the second interface. 
 
     
     
         14 . The panel of  claim 1  further comprising:
 a second cementitious layer covering the second face of the insulative core; 
 a second interface between the second cementitious layer and the insulative core; and 
 a second sealing cap, the second sealing cap at least partially sealing the second interface. 
 
     
     
         15 . The panel of  claim 1  wherein the sealing cap extends along at least three edge surfaces of the panel. 
     
     
         16 . The panel of  claim 1  further comprising:
 an opening for receiving at least one of a window and a door; and 
 an opening sealing cap, the opening sealing cap extending longitudinally along at least a portion of one edge surface which defines the opening, the opening sealing cap sealing the edge surface. 
 
     
     
         17 . The panel according to  claim 16  wherein the opening sealing cap extends longitudinally along all of the edge surfaces which define the opening. 
     
     
         18 . The panel of  claim 1  wherein the sealing cap substantially prevents moisture from penetrating into the panel. 
     
     
         19 . The panel of  claim 1  wherein the sealing cap substantially prevents one or more pests from penetrating into the panel. 
     
     
         20 . A method for fabricating a prefabricated panel, the method comprising applying a sealing cap at least partially along at least one edge surface of the panel, the sealing cap sealing at least one interface formed between an insulative core of the panel and a cementitious layer which covers a surface of the insulative core. 
     
     
         21 . The method of  claim 20  wherein the sealing cap is wrapped along the insulative core prior to casting the cementitious layer.