This invention relates to prefabricated, lightweight, multi-component structural modular building panels and modular building systems. The said panels are framed with edge members that have a unique connecting shape, making them modular. The multi-component panel allows for design flexibility and the mass manufacturing of its components. Connectors serve as a link to assemble the panels together, and to connect them to corners, floors or foundations, roof panels and the roof apex member, and or other conventional construction elements. Connectors and members, all with unique connecting shapes, coupled with the said panels, create a structural wall, roof, similar structure or building system. Assembled panels and members incorporate the primary building structure and the building envelope. The assembled panels, members and other components of the building system, in part or whole, can be flat packed for easy transport and shipping, and can be assembled quickly and easily with semi-skilled labor.

This invention relates to prefabricated, lightweight, multi-component structural modular building panels and modular building systems. The said panels are framed with edge members that have a unique connecting shape, making them modular. The multi-component panel allows for design flexibility and the mass manufacturing of its components. Connectors serve as a link to assemble the panels together, and to connect them to corners, floors or foundations, roof panels and the roof apex member, and or other conventional construction elements. Connectors and members, all with unique connecting shapes, coupled with the said panels, create a structural wall, roof, similar structure or building system. Assembled panels and members incorporate the primary building structure and the building envelope. The assembled panels, members and other components of the building system, in part or whole, can be flat packed for easy transport and shipping, and can be assembled quickly and easily with semi-skilled labor.

An exterior wall features interior and exterior insulation layers that comprise facer-laminated foam insulation panels having battens recessed into foam cores thereof at interior and exterior faces of the interior and exterior layers, respectively. A first set of spacer boards between the insulation layers provide an offset therebetween, and thereby create an array of air-filled void spaces for further insulative effect. At the interior side of the interior panels, a second set of spacer boards are installed for offset mounting of interior finishings (e.g. drywall) thereto, thereby creating another insulative array of air-filled void spaces between the interior insulation panels and the interior finishings. Exterior cladding placed directly over the exterior insulation panels is fastened to the battens thereof. On-site construction with a framing nailer is fast and convenient, creating a thermally efficient wall without need for batting insulation, poly sheeting vapour barrier, building wrap or exterior sheathing.

An exterior wall features interior and exterior insulation layers that comprise facer-laminated foam insulation panels having battens recessed into foam cores thereof at interior and exterior faces of the interior and exterior layers, respectively. A first set of spacer boards between the insulation layers provide an offset therebetween, and thereby create an array of air-filled void spaces for further insulative effect. At the interior side of the interior panels, a second set of spacer boards are installed for offset mounting of interior finishings (e.g. drywall) thereto, thereby creating another insulative array of air-filled void spaces between the interior insulation panels and the interior finishings. Exterior cladding placed directly over the exterior insulation panels is fastened to the battens thereof. On-site construction with a framing nailer is fast and convenient, creating a thermally efficient wall without need for batting insulation, poly sheeting vapour barrier, building wrap or exterior sheathing.

Light weight composites with high flexural strength comprise epoxy foam sandwiched between two layers of facing material have high strength and low weight and can be used to replace steel structures. The facing layer may be fibrous material especially glass or carbon fibres, the facing material is preferably embedded into the epoxy matrix. Alternatively they may be matching box structures or concentric metal tubes. The sandwich structures may be prepared by laying up the fibre; coating and/or impregnating the layer with epoxy resin, laying a layer of heat activatable foamable epoxy material, providing a further layer of the fibrous material optionally coated and/or impregnated with epoxy resin on the foamable material and healing to foam and cure the epoxy materials. Alternatively they may be formed by extrusion of the foamable material between the surface layers.

Light weight composites with high flexural strength comprise epoxy foam sandwiched between two layers of facing material have high strength and low weight and can be used to replace steel structures. The facing layer may be fibrous material especially glass or carbon fibres, the facing material is preferably embedded into the epoxy matrix. Alternatively they may be matching box structures or concentric metal tubes. The sandwich structures may be prepared by laying up the fibre; coating and/or impregnating the layer with epoxy resin, laying a layer of heat activatable foamable epoxy material, providing a further layer of the fibrous material optionally coated and/or impregnated with epoxy resin on the foamable material and healing to foam and cure the epoxy materials. Alternatively they may be formed by extrusion of the foamable material between the surface layers.

Described herein is a building panel and related building systems, the building panel having a first major surface opposite a second major surface, the building panel comprising a core comprising a first body comprising a first fibrous material; and a second body comprising a second fibrous material, a veneer facing layer coupled to the core, the veneer facing layer comprising a plurality of perforations.

Described herein is a building panel and related building systems, the building panel having a first major surface opposite a second major surface, the building panel comprising a core comprising a first body comprising a first fibrous material; and a second body comprising a second fibrous material, a veneer facing layer coupled to the core, the veneer facing layer comprising a plurality of perforations.

A building panel structure is disclosed, in which building panels are used to form a structure. Roof panels and roof panel tiles are disclosed, which can be used to form the roof of the structure. The roof panels and the building panels include a core and a coating covering a portion of the core. In some embodiments the core consists of a frame and at least one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes ceramic material. In some embodiments the coating includes a first layer and a second layer. In some embodiments the coating is used to retrofit existing wall structures. The roof panel and the roof tile can be shaped, formed, and colored to look like traditional roof tiles such as shake roof tiles or Spanish roof tiles.

A building panel structure is disclosed, in which building panels are used to form a structure. Roof panels and roof panel tiles are disclosed, which can be used to form the roof of the structure. The roof panels and the building panels include a core and a coating covering a portion of the core. In some embodiments the core consists of a frame and at least one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes ceramic material. In some embodiments the coating includes a first layer and a second layer. In some embodiments the coating is used to retrofit existing wall structures. The roof panel and the roof tile can be shaped, formed, and colored to look like traditional roof tiles such as shake roof tiles or Spanish roof tiles.