Seamless reinforced concrete structural insulated panel

1. A structural insulated panel comprising:

a core of thermally insulating material having a first side and a second side opposite the first side;

a first skin coupled to the first side of the core;

a second skin coupled to the second side of the core; and

a stud extending at least partly across a distance between the first skin and the second skin, the stud being an integral part of the first skin,

wherein the first skin, the second skin, or both the first and second skins include a sheet of reinforced concrete material, the sheet of reinforced concrete material including:

a cement including calcium sulfoaluminate (CSA) cement in an amount greater than 10% by weight and bonding polymers in an amount less than 5% by weight, and

a reinforcing material disposed in at least a portion of the CSA cement.

2. The structural insulated panel of claim 1 , wherein the cement consists essentially of CSA cement.

3. The structural insulated panel of claim 1 , wherein the cement further includes Portland cement.

4. The structural insulated panel of claim 3 , wherein the reinforced concrete material further includes at least one of a pozzolan, an accelerator, a shrinkage reducing agent, or a hydration stabilizing agent.

5. The structural insulated panel of claim 1 , wherein the core of thermally insulating materials comprises at least one of polystyrene foam, polyurethane foam, polyisocyanurate foam, foamed or aerated concrete, or concrete mixed with one of more materials having a density less than concrete.

6. The structural insulated panel of claim 1 , wherein both the first and second skins are coupled directly to the core without a separate adhesive or binder.

7. The structural insulated panel of claim 1 , wherein the reinforced concrete material further comprises a pozzolan.

8. The structural insulated panel of claim 1 , wherein the reinforcing material comprises at least one of loose fibers, mesh material, woven or textile material, a lattice structure, or wire material.

9. The structural insulated panel of claim 1 , wherein the reinforcing material comprises at least one of glass, cellulose, metal, plastic, or ceramic.

10. The structural insulated panel of claim 1 , further comprising a plasticizer and an aggregate.

11. The structural insulated panel of claim 1 , wherein the first skin, the second skin, or both the first and second skins have a thickness of at least about 0.125 inch and at most about 1 inch.

12. The structural insulated panel of claim 1 , wherein the first skin, the second skin, or both the first and second skins have a first region having a thickness of at least about 0.125 inch and at most about 0.5 inch, and

wherein the first skin, the second skin, or both the first and second skins have a second region having a thickness greater than the thickness of the first region.

13. The structural insulated panel of claim 1 , wherein the first skin, the second skin, or both the first and second skins include an area within a perimeter of the respective skin(s) that is void of concrete material.

14. The structural insulated panel of claim 1 , wherein the first skin, the second skin, or both the first and second skins have a continuous seamless length greater than about 8 feet.

15. The structural insulated panel of claim 1 , wherein the first skin, the second skin, or both the first and second skins have a continuous seamless length of at least about 40 feet.

16. The structural insulated panel of claim 1 , wherein the reinforced concrete material consists essentially of:

the CSA cement;

reinforcing material;

pozzolan;

the bonding polymers;

aggregate; and

water.

17. The structural insulated panel of claim 1 , wherein the reinforced concrete material consists essentially of:

the CSA cement;

Portland cement;

reinforcing material;

pozzolan;

the bonding polymers;

aggregate; and

water.

18. The structural insulated panel of claim 1 , wherein the stud extends completely across a distance between the first skin and the second skin.

19. The structural insulated panel of claim 1 , wherein the stud extends only partially across a distance between the first skin and the second skin.

20. The structural insulated panel of claim 1 , wherein the sheet of reinforced concrete material comprises a cement including CSA cement in an amount greater than 10% and up to about 80% by weight, polymers in an amount of about 0.5% up to less than 5% by weight, one or more aggregates in an amount between 0% and about 70% by weight, and one or more reinforcing materials in an amount between about 0.5% and about 10% by weight, and water.

21. The structural insulated panel of claim 1 , wherein the sheet of reinforced concrete material comprises a cement including CSA cement in an amount between about 35% and about 45% by weight, polymers in an amount between about 1% and about 3% by weight, one or more aggregates in an amount between about 20% and about 60% by weight, and one or more reinforcing materials in an amount between about 1% and about 5% by weight, and water.

22. The structural insulated panel of claim 1 , wherein the reinforcing material is distributed unevenly throughout one or both of the skins.

23. A structural insulated panel comprising:

a core of thermally insulating material having a first side and a second side opposite the first side;

a first skin coupled directly to the first side of the core;

a second skin coupled directly to the second side of the core; and

a stud extending at least partly across a distance between the first skin and the second skin, the stud being an integral part of the first skin,

wherein the first skin, the second skin, or both the first and second skins include a sheet of reinforced concrete material, the sheet of reinforced concrete material including:

a cement including calcium sulfoaluminate (CSA) cement in an amount greater than 10% by weight and bonding polymers in an amount less than 5% by weight, a plasticizer, an aggregate and

a reinforcing material disposed in at least a portion of the CSA cement, the reinforcing material including at least one of glass, cellulose, metal, plastic, or ceramic, and the reinforcing material being in the form of at least one of loose fibers, mesh material, woven or textile material, a lattice structure, or wire material.

24. The structural insulated panel of claim 23 , wherein the stud extends completely across a distance between the first skin and the second skin.

25. The structural insulated panel of claim 23 , wherein the stud extends only partially across a distance between the first skin and the second skin.

26. A structural insulated panel comprising:

a core of thermally insulating material having a first side and a second side opposite the first side;

a first skin coupled to the first side of the core;

a second skin coupled to the second side of the core; and

wherein the first skin, the second skin, or both the first and second skins include a sheet of reinforced concrete material, the sheet of reinforced concrete material including:

a cement including calcium sulfoaluminate (CSA) cement in an amount greater than 10% by weight and bonding polymers in an amount less than 5% by weight, and a reinforcing material disposed in at least a portion of the CSA cement.

27. The structural insulated panel of claim 26 , wherein at least one of the first skin and the second skin is directly coupled to one of the first and second sides of the core without a separate adhesive or binder.

28. The structural insulated panel of claim 26 , wherein at least one of the first skin and the second skin comprises a cement including CSA cement in an amount greater than 10% and up to about 80% by weight, polymers in an amount of about 0.5% up to less than 5% by weight, one or more aggregates in an amount between 0% and about 70% by weight, and one or more reinforcing materials in an amount between about 0.5% and about 10% by weight, and water.

29. The structural insulated panel of claim 26 , wherein at least one of the first skin and the second skin comprises a cement including CSA cement in an amount between about 35% and about 45% by weight, polymers in an amount between about 1% and about 3% by weight, one or more aggregates in an amount between about 20% and about 60% by weight, and one or more reinforcing materials in an amount between about 1% and about 5% by weight, and water.

30. The structural insulated panel of claim 26 , further comprising a reinforcing material distributed unevenly throughout at least one of the first skin and the second skin.