Construction components and systems fabricated using extruded materials are disclosed. A particular embodiment includes: a sheet fabricated from an extruded material; and a core structure internal to the sheet, the core structure including voids, the voids being triangular-shaped and arranged in an alternately inverted pattern.

A panel comprising internal strips or regions reinforced with nanomaterials having high load carrying capacity.

A method of forming a building panel includes embossing dimples into a sheet, where the dimples extend outward from a plane, and expanding a foam core onto the plane and into portions of the dimples. The method may include forming dimples that are convex relative to the plane and the foam core or the sheet having a thin foil having a plastic protective coating. The method may include attaching a cellulosic layer to the foam core opposite the plane. Additionally, flow channels may be formed in the sheet between the dimples, such that expanding the foam core onto the plane substantially fills both the dimples and the flow channels. The method may include embossing concave dimples onto the plane and the foam core, such that expanding the foam core onto the plane substantially fills the concave dimples. The foam core and sheet may bond without adhesives.

A composite panel for use in applications such as mobile homes, boats, buses, RVs, or other panels used typically in transportation applications, where a single piece, water resistant, lightweight panel with patterned high-strength areas is needed. The composite panel generally includes internal preforms made of low-density material such as urethane foam, which create patterned structural portions of the panel during the molding process. The patterned structural portions are formed by a maze-like region within a mold, into which composite matrix material is infused. The patterned structural portions have high strength compared to the other regions of the panel, and can be used for structural support or for retaining fasteners for appliances, walls, etc.

A composite panel for use in applications such as mobile homes, boats, buses, RVs, or other panels used typically in transportation applications, where a single piece, water resistant, lightweight panel with patterned high-strength areas is needed. The composite panel generally includes internal preforms made of low-density material such as urethane foam, which create patterned structural portions of the panel during the molding process. The patterned structural portions are formed by a maze-like region within a mold, into which composite matrix material is infused. The patterned structural portions have high strength compared to the other regions of the panel, and can be used for structural support or for retaining fasteners for appliances, walls, etc.

A composite building system comprising a structural frame, walls, floor, and roof is made of pultrusion fiber reinforced polymer (PFRP) material. A combination of PFRP, stainless steel screws and flexible epoxy can be used in the manufacture of a mobile or fixed structure. During assembly, an intumescent fire barrier can be applied to the PFRP components. Unlike traditional building materials, an exterior waterproof finish coating is not required when using a PFRP wall, floor, and roof assembly. The PFRP wall and wall assembly can be used with both PFRP structural framing and traditional framing materials, such as concrete, steel, or wood, allowing the PFRP wall and wall assembly to be used as a mid-rise or high-rise curtain wall.

A composite building system comprising a structural frame, walls, floor, and roof is made of pultrusion fiber reinforced polymer (PFRP) material. A combination of PFRP, stainless steel screws and flexible epoxy can be used in the manufacture of a mobile or fixed structure. During assembly, an intumescent fire barrier can be applied to the PFRP components. Unlike traditional building materials, an exterior waterproof finish coating is not required when using a PFRP wall, floor, and roof assembly. The PFRP wall and wall assembly can be used with both PFRP structural framing and traditional framing materials, such as concrete, steel, or wood, allowing the PFRP wall and wall assembly to be used as a mid-rise or high-rise curtain wall.

A composition is provided comprising: a) polyvinylchloride, b) inorganic solid particles, and c) a polymer having a polyether segment, wherein at least 60 mol-% of the end groups of the polymer are selected from the group consisting of carboxylic acid groups and hydroxyl groups, and wherein at least a part of the end groups of the polymer is a carboxylic acid group, wherein the carboxylic acid end groups are linked to the polyether segment via a linking segment comprising an ester group.

A method of making a glass mat includes providing an assembly of glass fibers, applying a binder composition to the assembly of glass fibers, wherein the binder includes an organic resin, and curing the binder composition while dimensionally constraining the assembly of glass fibers. Dimensional constraining includes directly contacting a first major surface and a second major surface of the assembly of glass fibers between two substantially parallel surfaces. Further provided is a glass mat that includes an assembly of glass fibers, wherein the assembly of glass fibers are substantially randomly oriented with a tensile anisotropy of less than about 6 in any two directions. The glass mat has a decreased surface roughness and a decreased caliper compared to an equivalent glass mat having an assembly of naturally packed glass fibers with an equivalent fiber diameter size.

A method of making a glass mat includes providing an assembly of glass fibers, applying a binder composition to the assembly of glass fibers, wherein the binder includes an organic resin, and curing the binder composition while dimensionally constraining the assembly of glass fibers. Dimensional constraining includes directly contacting a first major surface and a second major surface of the assembly of glass fibers between two substantially parallel surfaces. Further provided is a glass mat that includes an assembly of glass fibers, wherein the assembly of glass fibers are substantially randomly oriented with a tensile anisotropy of less than about 6 in any two directions. The glass mat has a decreased surface roughness and a decreased caliper compared to an equivalent glass mat having an assembly of naturally packed glass fibers with an equivalent fiber diameter size.