A wall panel may have a rigid layer, a first insulation layer made from a two-part rigid urethane pour foam, and a second insulation layer made from a phase change material. The first insulation layer maybe chemically bonded to the rigid layer and may also be bonded to the phase change layer. The first insulation layer may be positioned between the second insulation layer and the rigid layer. The rigid layer may be a finished surface or a veneer layer may be applied to the rigid layer.

This invention is an additively manufactured wall panel using computer aided design (CAD) and computer aided manufacturing (CAM) to design and manufacture multi-colored and multi-layered wall panels. This results in a variety of highly attractive, multi-colored wall panel faces ranging from brick, colored grout lines and multi-colored stones to multi-colored geometric designs. The design and manufacturing process greatly reduces the amount of precast cementitious materials by efficiently using higher quality materials. This reduces cost and weight while simultaneously producing a much more comprehensive, multi-functional wall panel complete with an interior frame, exterior insulation and an air, vapor and moisture barriers.

A method for assembling a brick pattern for forming a precast brick panel. The method includes conveying bricks in a row to a spacing station, spacing the bricks apart in a row at the spacing station according to a predetermined row pattern and to a predetermined row length by allowing the spacing between adjacent bricks to vary if required. The method then involves transferring the row of spaced bricks onto a generally planar support surface of a brick pattern assembly station. By this method, a plurality of rows of spaced bricks are assembled adjacent each other on the support surface of the brick pattern assembly station to form a brick pattern.

This invention is an additively manufactured wall panel using computer aided design (CAD) and computer aided manufacturing (CAM) to design and manufacture multi-colored and multi-layered wall panels. This results in a variety of highly attractive, multi-colored wall panel faces ranging from brick, colored grout lines and multi-colored stones to multi-colored geometric designs. The design and manufacturing process greatly reduces the amount of precast cementitious materials by efficiently using higher quality materials. This reduces cost and weight while simultaneously producing a much more comprehensive, multi-functional wall panel complete with an interior frame, exterior insulation and an air, vapor and moisture barriers.

A fiber reinforced surface covering for application to a structure, comprising at least one structural body comprising a resilient construction material with a top side and a bottom side, a flexible base coupled to the bottom side of the structural body, a spaced gap disposed between the at least one structural body and an adjacent second body, and wherein the spaced gap has a portion of the base that is substantially overlaid with the resilient construction material and configured to receive a filler material.

A wall panel for installation on a supporting wall includes a facing surface that includes a plurality of separate and spaced apart design elements. The design elements define a channel therebetween. The panel also includes a backing surface having at least one rib opposite the channel. The rib extends transversely across the backing surface, such as a parallel to one of the upper or lower edges of the panel or at an angle between 0 and 90 relative to one of the upper or lower edges of panel. Fasteners are engagable through the channel and the rib for securing the wall panel to the supporting wall. Upon installation of the wall panel on the supporting wall, one or more air gaps are defined by the rib and the backing surface opposite the design elements. The rib provides additional material opposite the channel to prevent the panel from breaking during installation.

Disclosed herein are composite building materials having at least one textured surface. The textured surface includes at least a plurality of particles. The textured surface closely mimics conventional building materials. The building materials can contain an image printed using ink jet printing methods with inks optimized for enhanced color stability.

This invention is an additively manufactured wall panel using computer aided design (CAD) and computer aided manufacturing (CAM) to design and manufacture multi-colored and multi-layered wall panels. This results in a variety of highly attractive, multi-colored wall panel faces ranging from brick, colored grout lines and multi-colored stones to multi-colored geometric designs. The design and manufacturing process greatly reduces the amount of precast cementitious materials by efficiently using higher quality materials. This reduces cost and weight while simultaneously producing a much more comprehensive, multi-functional wall panel complete with an interior frame, exterior insulation and an air, vapor and moisture barriers.

A wall panel may have a rigid layer, a first insulation layer made from a two-part rigid urethane pour foam, and a second insulation layer made from a phase change material. The first insulation layer maybe chemically bonded to the rigid layer and may also be bonded to the phase change layer. The first insulation layer may be positioned between the second insulation layer and the rigid layer. The rigid layer may be a finished surface or a veneer layer may be applied to the rigid layer.

A building panel assembly is disclosed. The building panel assembly consists of a first layer having one or more laminated softwood or hardwood lumber coupled to each other using finger-joints. Further, a second layer is attached to the first layer, and acts as a thermal insulation for the building panel. Further, an optional third layer is attached to the second layer, and acts as a fire retarding layer for the building panel. Further, one or more framing members are coupled to the second layer and optionally to the third layer, and transversely spaced from each other. The one or more framing members have transversely oriented passageways for passage of wires and pipes.