Structural elements and method for fabricating structural elements

1 . A composite panel structure comprising:

a flange beam assembly including:

a web assembly; and

a first flange assembly attached in an essentially perpendicular fashion to the web assembly; and

at least two panel assemblies, wherein each panel assembly includes:

a foam layer;

a first high-density material layer secured to the foam layer; and

at least one recess configured to receive at least a portion of the first flange assembly.

2 . The composite panel structure of claim 1 wherein the foam layer is at least partially constructed of a vinyl acetate-ethylene copolymer.

3 . The composite panel structure of claim 1 wherein the first high-density material layer is a poly-urea material layer.

4 . The composite panel structure of claim 1 wherein the first high-density material layer is a cement-based material layer.

5 . The composite panel structure of claim 1 wherein the composite panel structure is selected from the group consisting of: a building wall panel structure; a roof panel structure; a ceiling panel structure; a floor panel structure; a privacy wall panel structure; a sea wall panel structure; and any combination thereof.

6 . The composite panel structure of claim 1 further comprising a second high-density material layer.

7 . The composite panel structure of claim 6 wherein the foam layer is disposed between the first and second high-density material layers.

8 . The composite panel structure of claim 1 wherein the flange beam assembly includes a second flange assembly attached in an essentially perpendicular fashion to the web assembly.

9 . A method of fabricating a composite panel structure comprising:

providing a flange beam assembly including a web assembly and a first flange assembly attached in an essentially perpendicular fashion to the web assembly;

providing a layer of foam including at least one recess configured to receive at least a portion of the first flange assembly; and

disposing a first high-density material layer onto the layer of foam.

10 . The method of claim 9 wherein the layer of foam is at least partially constructed of a vinyl acetate-ethylene copolymer.

11 . The method of claim 9 wherein the composite panel structure is selected from the group consisting of a building wall panel structure, a roof panel structure, a ceiling panel structure, a floor panel structure, a privacy wall panel structure, a sea wall panel structure, and any combination thereof.

12 . The method of claim 9 wherein the first high-density material layer is a poly-urea material layer.

13 . The method of claim 9 wherein the first high-density material layer is a cement-based material layer.

14 . The method of claim 9 further comprising disposing a second high-density material layer onto the layer of foam.

15 . The method of claim 14 wherein the foam layer is disposed between the first and second high-density material layers.

16 . The method of claim 9 wherein the flange beam assembly includes a second flange assembly attached in an essentially perpendicular fashion to the web assembly.