Poly-bonded framed panels
A one layer building panel derives its structural integrity from a foam forming the layer that bonds to horizontal and vertical stud members with a mesh material disposed therein. The vertical members can be provided at the edges of the building panel. The horizontal members can be provided at the edges of the building panel and together with the vertical member form a peripheral frame for the building panel. The foam is bonded to the horizontal and vertical stud members using above ambient temperatures and pressures. Building panels can be connected to one another to construct a building wall and ceiling using stud members having an interlocking capabilities. The building panels can be inserted into tracks secured to a floor using anchors.
1. A building panel including studs used in construction having structural integrity, comprising:
a peripheral frame configured from the studs, wherein the studs include a top horizontal stud member, a bottom horizontal stud member, a left vertical stud member, and a right vertical stud member, wherein a first end portion of the top horizontal stud member joins to a first end portion of left vertical stud member, a second end of the top horizontal stud member joins to a first end portion of right vertical stud member, a first end portion of the bottom horizontal stud member joins to a second end portion of left vertical stud member, and a second end portion of the bottom horizontal stud member joins to a second end of the right vertical stud member;
a foam formed within the peripheral frame, wherein the foam is bonded to the peripheral frame, a first side of the foam defines an exterior surface of the building panel, and a second side of the foam defines an interior surface of the building panel; and
a mesh provided within, and bonded to, the foam and coupled to the studs.
2. The building panel of claim 1 , wherein the structural integrity of the building panel is derived from the bonding of the foam to the peripheral frame.
3. The building panel of claim 1 , wherein the foam comprises a thermoplastic material or a thermoset material.
4. The building panel of claim 1 , wherein the top horizontal stud member, the bottom horizontal stud member, the right vertical stud member, and the left vertical stud member are constructed from one of: metal, aluminum, wood, and plastic.
5. The building panel of claim 1 , wherein the top horizontal stud member, the bottom horizontal stud member, the right vertical stud member, and the left vertical stud member are configured as one of: a conventional stud, and a c-shaped stud.
6. The building panel of claim 1 , wherein the foam and the mesh extends to the outer boundary of the peripheral frame.
7. The building panel of claim 1 , wherein at least one of the right vertical stud member, the left vertical stud member, top horizontal stud member, and bottom horizontal stud member is an interlocking stud operable to interlock with an interlocking stud of an adjacent structural component.