Abstract: A prefabricated building panel includes first and second side panel members. A thermally insulating core is disposed between those side panel members. A first panel end surface includes a pair of spaced projections defining a channel-way. A second panel end surface includes a pair of spaced channels and a thermal barrier plug. Two adjacent building panels may be interconnected by engaging the pair of spaced projections at the first end of the first panel in the pair of spaced channels in the second end of the second panel while simultaneously engaging the thermally insulating plug at the second end of the second panel in the channel-way at the first end of the first panel.

Abstract: A continuous process for making a structural foam panel with a stiffener is described, and a continuous assembly line for the process is described. The continuous assembly line includes decoilers for decoiling top and bottom skins, uncoilers for releasing top and bottom stiffeners, straighteners for threading and attaching the stiffeners to the skins, respectively, roll formers for shaping both skins and stiffeners into a structural shape, a foam injector for injecting foam between the skins to form an integrated continuous panel, a foam conveyor for pressing the integrated continuous panel, an oven for curing the integrated continuous panel, a clamp and cut-off saw for cutting the continuous panel, and a computer to control the saw to cut the continuous panel into selected kits of discrete panels to assemble selected buildings.