The present invention is directed to a multi-purpose panel member which may be utilized as any surface or support beam in a structure. In a preferred embodiment, the panel may be extruded monolithically from aluminum. Also disclosed are systems for assembling structures from the panels utilizing a plurality of other components, which are also preferably extruded from aluminum.

Systems and methods are described herein for a composite building panel for use in a panelized structure. In some aspects, a composite building panel may include: a core defining a channel formed via subtractive manufacturing; a utility conduit placed or formed in and bonded to the channel and enclosed by the core, where the utility conduit exits the core along a first mating edge of the core; and first and second skin elements bonded to the core to form a layered structure. In some cases, the layered structure may also include a reinforced block coupled to at least the first fiber-reinforced skin element and defining part of the first mating edge, where the reinforced block defines a first portion of the first mating edge for mating with another composite building panel of the panelized structure.

A building system that includes a modular panel with side members, at least one of the side members having an associated coupling for hooked connection with a corresponding shaped fixture of an adjacent structure, the coupling and fixture being adapted to be held together by a locking device that, when engaged, acts to lock the structure and the side member together and, when disengaged, allows for play between the panel and structure in order to free the panel from the structure.

A building system that includes a modular panel with side members, at least one of the side members having an associated coupling for hooked connection with a corresponding shaped fixture of an adjacent structure, the coupling and fixture being adapted to be held together by a locking device that, when engaged, acts to lock the structure and the side member together and, when disengaged, allows for play between the panel and structure in order to free the panel from the structure.

The invention is for a modular building unit (10, 200, 210) for use in constructing a building. The building unit (10, 200, 210) has a planar body (12) having two major side faces (12.1) and two ends (12.2) between each side face (12.1), and a connection interface (28, 30) provided at each of the ends, for connecting similar building units (10, 200, 210) with complemental connection interfaces. The body (12) comprises three walls (14, 16, 18) arranged side-to-side and transversely spaced from each other, the three walls (14, 16, 18) thus defining two planar spaces (20, 22) therebetween, and a plurality of reinforcing webs (24) in the first space, for providing structural support to the building unit (10, 200, 210). The second space (22) defines at least one hollow cavity for receiving a matched insulation insert (25) thereby to impart insulating properties to the building unit (10, 200, 210).

A load bearing building panel having a first sheet intended to provide an inner building surface, a second sheet intended to provide an outer building surface, and an insulating foam core sandwiched between them. The sheet that provides the inner building surface is corrugated to define co-planar portions separated by a plurality of channels which are dimensioned so as to be able to accommodate standard size electrical boxes and/or plumbing pipes. Advantageously, the other sheet is also corrugated to define a plurality of channels so that a plurality of panels can be stacked in a partially nesting relationship.

A cellular structure may include a plurality of cells each having a twelve-cornered cross section. The twelve-cornered cross section may include twelve sides and twelve corners creating eight internal angles and four external angles. Each cell may include a plurality of longitudinal walls extending between a top and a bottom of the cell, the longitudinal walls intersecting to create corners of the cell. A structural component may include at least one wall surrounding a component interior space with a cellular structure having at least two cells being positioned within the interior space. A sandwich structure may include first and second substantially planar structures, and a cellular structure with at least two cells positioned between the first and second substantially planar structures.

A method for producing a composite part. The method includes the following steps: stacking a first mat, a spacer and a second mat in a heatable mold; at least one of the mats including a continuous web of fibers impregnated with a thermosetting resin; and compressing and heating of the stack by the heatable mold, in order to polymerize the thermosetting resin. The stacking step includes the deposition, in a heatable mold, of a first and a second filtration layer, in contact respectively with the first and second mats, on the opposite side from the spacer. The filtration layers are porous to steam and relatively less porous to the thermosetting resin. During the compression and heating step steam is evacuated from the mold.

A composite frame for vehicles formed with a honeycomb or similar core laminated on the top and bottom sides with a layer of material joined by an adhesive layer. One or more structural beams or stringer are interposed between the top and bottom layer of the composite frame running part or all of the length or width of the composite frame. Each of these structural members may also be joined to the top and bottom material as well as the adjacent honeycomb or by a layer of adhesive or by other means. One embodiment of the frame may be perfectly flat along a horizontal axis. A second embodiment may conform to any curvature, angle or combination specified.

A composite frame for vehicles formed with a honeycomb or similar core laminated on the top and bottom sides with a layer of material joined by an adhesive layer. One or more structural beams or stringer are interposed between the top and bottom layer of the composite frame running part or all of the length or width of the composite frame. Each of these structural members may also be joined to the top and bottom material as well as the adjacent honeycomb or by a layer of adhesive or by other means. One embodiment of the frame may be perfectly flat along a horizontal axis. A second embodiment may conform to any curvature, angle or combination specified.