Granted Patent B2

US 12,546,130 · App. 18/347,242 · Granted Feb 10, 2026

Inventor: Jeff Friedman (Reno, NV)

E04G23/02B32B3/12B32B5/022B32B5/265B32B27/12B32B27/36B32B37/24B32B2250/40B32B2260/023B32B2260/046B32B2262/0276B32B2262/101B32B2305/076B32B2305/18B32B2315/085B32B2367/00B32B2607/00

Abstract

Claims (52)

1 . A composite panel system comprising:

a first base wall of an existing vault;

the panel system configured to attach to, reinforce, and seal the first base wall;

a first composite panel having: a first side comprising a fluid impermeable, non-porous outer layer; and a second side facing the first base wall of the existing vault to which the first panel is attached, the second side comprising a resin with an embedded mechanical bonding agent;

at least one spacer board fixed to and extending from the second side of the first composite panel toward the first base wall;

a void between the second side of the first composite panel and the first base wall;

a fill configured to be poured into a space between the first panel, each spacer board, and the first base wall to fill the void therebetween;

the fill configured to harden to a solid;

the fill configured to be mechanically bonded to the second side of the first composite panel when hardened and mechanically bonded to the first base wall;

a plurality of transverse conduits formed through the first composite panel and the at least one spacer board;

each transverse conduit configured for passage of a fastener therethrough; and

each fastener coupled to the first base wall and configured to attach the first composite panel to the first base wall.

2 . The composite panel system of claim 1 , the embedded mechanical bonding agent selected from a group consisting of: plastic chips, crushed plastic material, and aggregate.

3 . The composite panel system of claim 1 , the first composite panel comprising: a honeycomb layer with fiberglass reinforcing layers.

4 . The composite panel system of claim 3 , the composite panel further comprising: at least one polyester fleece layer, wherein the resin layer is applied to the polyester fleece layer.

5 . The composite panel system of claim 1 , the at least one spacer board comprising: a honeycomb layer with fiberglass reinforcing layers.

6 . The composite panel system of claim 1 , wherein the first side of the first composite panel has a roughened perimeter.

7 . The composite panel system of claim 1 , further comprising: a second composite panel immediately adjacent the first composite panel, the second composite panel having a roughened perimeter; and a fiberglass panel formed so as to seal the roughened perimeter of the first composite panel to the roughened perimeter of the second composite panel.

8 . The composite panel system of claim 7 , wherein the second composite panel is parallel to the first composite panel.

9 . The composite panel system of claim 1 , the first composite panel comprising:

a first polyester resin layer at the first side thereof,

a first polyester fleece layer beneath the first polyester layer;

a fiberglass layer beneath the first polyester fleece layer

a center, honeycomb layer;

a second fiberglass layer abutting the center, honeycomb layer opposite the first fiberglass layer;

a second polyester fleece layer beneath the second fiberglass layer;

wherein the resin layer with the embedded mechanical bonding agent abuts the second polyester fleece layer and forms the second side of the first composite panel.

10 . The composite panel system of claim 1 , said fill comprising high-flow grout.

11 . The composite panel system of claim 1 , said fill comprising aggregate fill.

12 . A method for reinforcing an existing vault formed of at least one base wall, comprising the steps of:

providing a first composite panel having: a first side comprising a fluid impermeable, non-porous outer layer; and a second side facing the first base wall to which the first panel is attached, the second side comprising a resin with an embedded mechanical bonding agent;

providing at least one spacer board extending from the second side of the first panel and toward the base wall so as to form a gap between each spacer board and the base wall;

each the spacer board increasing rigidity of the first composite panel;

providing a plurality of transverse conduits though the first composite panel and the spacer boards;

passing a fastener through each conduit to the base wall;

coupling each fastener directly to the base wall to attach the first panel to the base wall;

pouring a fill into a space between the first panel and the first base wall to fill the space therebetween;

allowing the fill to harden to a solid fill; and

the solid fill mechanically bonded to the second side of the first panel when hardened and in direct contact with the first base wall.

13 . The method of claim 1 , the embedded mechanical bonding agent comprising plastic chips.

14 . The method of claim 1 , the embedded mechanical bonding agent comprising coarse aggregate.

15 . The method of claim 1 , the first composite panel comprising:

a first polyester resin layer at the first side thereof;

a first polyester fleece layer beneath the first polyester layer;

a fiberglass layer beneath the first polyester fleece layer

a center; honeycomb layer;

a second fiberglass layer abutting the center; honeycomb layer opposite the first fiberglass layer;

a second polyester fleece layer beneath the second fiberglass layer;

wherein the resin layer with the embedded mechanical bonding agent abuts the second polyester fleece layer and forms the second side of the first composite panel.

16 . The method of claim 12 , further comprising:

positioning a second composite panel adjacent the first composite panel; and

applying a fiberglass seal over respective perimeter edges of the first composite panel and second composite panel so as to seal a junction therebetween.

Assignments (2)

Continuity (1)

References Cited (14)