A foam filled structural plank made from a plurality of structural beams assembled together to form a structure capable of supporting the weight of a building thereon, wherein the plurality of structural beams define an enclosure therebetween and an outer perimeter therearound; and a structural building foam such as having expanded polystyrene foam having a density from 1.5 to 3.0 PFC filling the enclosure.

Foam insulation boards having an improved shiplap edge for interfacing with one another are disclosed.

In one aspect, composite construction materials are described herein. In some embodiments, a composite construction panel comprises a substrate layer, a cover layer separated from the substrate layer by one or more spacers, and at least one mat disposed between the substrate layer and the cover layer, wherein the mat comprises at least one phase change material disposed in at least one phase change region.

Foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel overlying a front surface of the frame, and a polyurethane foam layer disposed in a cavity of the wall structure. The polyurethane foam layer has a density, as determined by ASTM D1622-14, of at least 44 kg/m.sup.3 and exhibits ASTM E84-16 Class A flame spread and smoke development characteristics. The polyurethane foam layer is the cured reaction product of a polyurethane foam-forming composition that includes a polyisocyanate, an aromatic polyester polyol having a functionality of greater than 2.5 and an OH number of at least 300 mg KOH/g, which is present in an amount of at least 50% by weight, based on the total weight of the polyurethane foam-forming composition less the weight of the polyisocyanate, a catalyst, and a blowing agent composition. The blowing agent composition includes water and a hydrofluoroolefin.

It is known that panels moulded for structural use can be subject to undesirable levels of shrinkage and this can complicate their end use or a building made from them. It is an object of the invention to go at least some way to addressing this problem. Accordingly there is provided a method of significantly reducing panel shrinkage in the production of a structural building panel. The method involves spraying polyurethane foam onto a rigid open mould such that the foam substantially embeds mesh, which prevents or significantly reduces shrinkage of the polyurethane foam. A skin of polyurea is then sprayed over the polyurethane to enhance structural strength of the panel.

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.

Modular wall panels having a frame of a plurality of frame components and at least one wall sheet affixed to the frame. The frame components may have angled ends, straight ends, or a combination thereof to collectively form a frame which may include corners. Each frame component includes an outer surface with at least one aperture configured to receive and retain an insert therein. The apertures are also configured to permit a cable(s) to pass therethrough for running cables and such through the interior of the wall panel. Connectors and spacers may be inserted into the apertures as inserts and bridge between adjacent panels to selectively connect the panels. Caps may be placed in empty apertures to cover the openings for aesthetic purposes. A wall system includes a plurality of such wall panels connected to one another along the outer surfaces of the frame components of their respective frames.

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.

The disclosure relates generally to methods, systems, and apparatus for assembling prefabricated wall panels, such as prefabricated wall panels constructed with a layer of insulation coupled to a pre-formed metal layer, with a wall panel fastening system. An insulated wall panel system, includes a first wall panel having an extended portion, a second wall panel having a recessed portion configured to receive the extended portion of the first wall panel. The wall panel system also includes a wall panel clip disposed between the first wall extended portion and the second wall panel recessed portion, the wall panel clip including a first web member and a second web member extending at an angle from the first web member, the first web member having a first end portion, a second end portion and a middle portion disposed between the first and second end portions, the second web member having a first end portion, a second end portion and a middle portion disposed between the first and second end portions. The wall panel system further includes that the first web member middle portion includes a through hole extending therethrough and the first and second end portion of the second web member each including a through-hole extending therethrough. The wall panel system further includes an internal fastener configured to connect at least one of first end portion or the second end portion to a portion of the second wall panel and the second wall panel to a building support structure. The wall panel system also includes a face fastener extending through the first wall panel and into the wall panel clip to secure the first wall panel to the second wall panel.

A non-wicking underlayment board and methods for forming the same. The non-wicking underlayment board includes a foam core formed of closed cell foam with reinforcement layers encapsulated within the foam core. Outer facings formed of mineral coated nonwoven fibers are positioned on opposite faces of the non-wicking underlayment panel. The non-wicking underlayment board is useful for efficient and cost effective installation of barriers and surfaces in water-resistant and waterproof environments.