Abstract: A dual platen molding machine for constructing a plurality of pre-insulated structural panels is disclosed that includes multiple safety features. The molding machine produces one or more panels that may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to provide structural integrity to the panels, and resulting wall. A chase may be formed horizontally in the panels to provide a wiring conduit through the panel. The molding machine is electrically operated to control the movement of a movable molding portion when closed upon a stationary molding portion. Steam may be controlled to fuse insulating material such as expandable polystyrene (EPS) in cavities formed between the movable mold and the stationary mold. No hydraulics is required to operate the dual platen molding machine, thus improving operating and maintenance costs. Moreover, steam hoses may be avoided, thereby improving overall safety.

Abstract: An apparatus and method for constructing pre-insulated structural panels is disclosed that has a tongue and groove assembly arrangement. Each panel may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to provide structural integrity to the panels, and resulting wall. The panels may be covered with siding, stucco, or similar materials. A chase may be formed horizontally in the panels to provide a wiring conduit through the panel. The panel may also provide when assembled, a vertical chase formed between the mated panels along the length of the panel for wiring. Acoustical properties may be formed in the surface of the EPS portions to provided added acoustical damping measures.

Abstract: An apparatus and method for constructing pre-insulated structural panels is disclosed that has a tongue and groove assembly arrangement. Each panel may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to provide structural integrity to the panels, and resulting wall. The panels may be covered with siding, stucco, or similar materials. A chase may be formed horizontally in the panels to provide a wiring conduit through the panel. The panel may also provide when assembled, a vertical chase formed between the mated panels along the length of the panel for wiring. Acoustical properties may be formed in the surface of the EPS portions to provided added acoustical damping measures.

Abstract: An apparatus and method for constructing pre-insulated structural panels is disclosed that has a tongue and groove assembly arrangement. Each panel may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to provide structural integrity to the panels, and resulting wall. The panels may be covered with siding, stucco, or similar materials. A chase may be formed horizontally in the panels to provide a wiring conduit through the panel. The panel may also provide when assembled, a vertical chase formed between the mated panels along the length of the panel for wiring. Acoustical properties may be formed in the surface of the EPS portions to provided added acoustical damping measures.

Abstract: A dual platen molding machine for constructing a plurality of pre-insulated structural panels is disclosed that includes multiple safety features. The molding machine produces one or more panels that may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to provide structural integrity to the panels, and resulting wall. A chase may be formed horizontally in the panels to provide a wiring conduit through the panel. The molding machine is electrically operated to control the movement of a movable molding portion when closed upon a stationary molding portion. Steam may be controlled to fuse insulating material such as expandable polystyrene (EPS) in cavities formed between the movable mold and the stationary mold. No hydraulics is required to operate the dual platen molding machine, thus improving operating and maintenance costs. Moreover, steam hoses may be avoided, thereby improving overall safety.

Abstract: A method for forming building products from heat insulated material and building products formed in accordance therewith includes providing a mold configured with inner dimensions equal to the desired configuration of the building material block; providing a fluid mixture of heat insulating material formed from a predetermined composition of ingredients; providing at least one rigid reinforcement member and placing the reinforcement member in the mold; introducing the fluid mixture into the mold with the at least one reinforcement member and allowing the fluid mixture to harden within the mold and removing the mixture from the mold resulting in a block of reinforced heat insulating building material. The present invention is also directed to a block of reinforced heat insulated building material according to the method.

Abstract: A method for forming building products from heat insulated material and building products formed in accordance therewith includes providing a mold configured with inner dimensions equal to the desired configuration of the building material block; providing a fluid mixture of heat insulating material formed from a predetermined composition of ingredients; providing at least one rigid reinforcement member and placing the reinforcement member in the mold; introducing the fluid mixture into the mold with the at least one reinforcement member and allowing the fluid mixture to harden within the mold and removing the mixture from the mold resulting in a block of reinforced heat insulating building material. The present invention is also directed to a block of reinforced heat insulated building material according to the method.

Abstract: A formulation for producing a heat insulating material and the method for making the same that uses an exothermic reaction and which depends on sodium silicate, sodium hydroxide, firing clay and iron silicon. The iron silicon reacts in the alkaline medium in an exothermic reaction that results in a high release of heat. As a result of the exothermic reaction, the formulation heats up to temperatures near 100.degree. C. The formulation then starts to harden. The evolved water steam and hydrogen form pores, which allows for an increase of many times the volume of the resulting heat insulating material. The self-heating reaction causes the formulation to lose water, which leads to an increase in the dielectric qualities of the material. Additionally, the iron silicon raises the heat resistance of the resulting heat insulating material.

Abstract: A low cost insulating panel for covering walls of existing structures has an expanded cellular core having complementary stepped side edges of differing width to define depressions in a combination of two panels. The panel has thin flat reinforcing strips along side edges extending upon a front face of the panel and therefrom into the stepped configurations at most to come in contact in the depression formed by two mating panels without extending to a back face of any panel.

Abstract: An improved molding structure for producing a building panel or the like of expanded cellular core material having reinforcing strips flush with surfaces thereof and including one or more indentations or depressions having reinforcing elements extending therein and anchored within the core.