Impact resistant building panels

Abstract

A composite building panel that includes a fabric reinforcing sheet between one of the metal skins and the core of the panel. The fabric reinforcing sheet, which is preferably made from aramid fibers improves the impact resistance and penetration resistance of the building panel without substantially increasing weight and without adding fuel content to the panel system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional edge view of one embodiment of a building panel according to the present invention.

FIG. 2 is an edge cross sectional view of another embodiment of a building panel according to the present invention.

FIG. 3 is a schematic view of a manufacturing process for a composite panel of the present invention.

Claims

1. A building panel, comprising: an outer metal skin;an inner metal skin;a polymer core;a fabric reinforcing sheet disposed between the one of the metal skins and the polymer core; andan adhesive disposed between the fabric reinforcing sheet and the outer metal skin, the adhesive securing the aramid sheet to the outer metal skin.

2. The building panel according to claim 1, wherein the fabric reinforcing sheet is made from a fiber having a strength of at least about 10 grams/denier.

3. The building panel according to claim 2, wherein the fabric reinforcing sheet is selected from the group consisting of aramid fibers, polyethylene fibers, polyester fibers, nylon fibers, and fiberglass fibers.

4. The building panel according to claim 2, wherein the aramid fiber sheet has a weight of about 5 oz./yd.2 to about 20 oz./yd.2.

5. The building panel according to claim 2, wherein the aramid fiber sheet has a thickness of about 0.01 in. (0.254 mm.) to about 0.03 in. (0.762 mm.).

6. The building panel according to claim 1, wherein the adhesive is selected from the group consisting of a multi-layer anhydride modified polyolefin adhesive and an anhydride modified high density polyethylene adhesive.

7. The building panel according to claim 6, wherein the adhesive has a thickness of about 0.002 in. (0.051 mm.) to about 0.006 in. (0.152 mm.).

8. The building panel according to claim 1, wherein the metal skin is selected from the group consisting of aluminum, aluminum alloys, stainless steel, galvanized steel, zinc, and titanium.

9. The building panel according to claim 8, wherein the metal skin is an aluminum alloy selected from the group consisting of 3XXX and 5XXX series aluminum alloys.

10. The building panel according to claim 8, wherein the metal skin has a thickness of about 0.01 in. (0.254 mm.) to about 0,03 in. (0.762 mm.).

11. The building panel according to claim 1, wherein the polymer core includes polymers selected from the group consisting of polyethylene and ethylene vinyl acetate.

12. The building panel according to claim 11, wherein the polymer core includes polyethylene, aluminum trihydrate, and a fire retardant.

13. The building panel according to claim 1, wherein the polymer core has a thickness less than about 1 inch (2.54 cm.).

14. The building panel according to claim 13, wherein the polymer core has a thickness of about 1.5 mm. (0.059 in.) to about 5 mm. (0.199 in.)

15. The building panel according to claim 1, wherein the polymer core has a density exceeding 20 lb./ft.3 (328.382 kg./m3).

16. The building panel according to claim 1, wherein the first adhesive includes two components, one of the two components having an affinity for the metal skin, and the other of the two layers having an affinity for the fiber reinforcing sheet or the polymer core.