Abstract: A method of producing an engineered composite structural panel by selecting a structural panel having at least two structural shells, an insulating material extending therebetween, and a plurality of truss members extending therebetween. A determination is made if the two or more structural shells act as a unitary composite structural panel. If the structural panel is not a unitary composite structural panel, then parameters of the panel are adjusted and it is further determined whether the panel is a unitary composite structural panel. Combined truss systems for strengthening the structural panels may be formed by combining ladder truss members with warren truss members, by superimposing the ladder truss members and warren truss members, and by superimposing ladder truss members with a warren truss member and another warren truss member that is inverted.

Abstract: A structural composite insulated panel having a plurality of truss members arrayed in substantially parallel relation at a substantially equal interval so as to define a plurality of cells therebetween. The panel has an insulating member disposed in each of the cells, the panel has two opposing elongated side panel surfaces defined by side surfaces of the cells, and two opposing end panel surfaces defined by the respective end surfaces of two outermost cells of the panel, the two side panel surfaces are substantially perpendicular to the two end panel surfaces and the plurality of truss members. The panel has a pair of prismatic members, each parallely engaged to the respective side panel surfaces. The panel has a pair of locking members, each at the respective end panel surfaces and engaged thereat to the prismatic members to provide compressive locking tension to the insulating members and the trusses in the panel.

Abstract: A machine for fabricating a composite structural panel is provided that receives trusses vertically and feeds them into a foam spray chamber driven by first and second drive mechanisms. The drive mechanisms form the filler material and maintain the trusses in place while a cutting blade trims off excess foam.

Abstract: A method of producing an engineered composite structural panel by selecting a structural panel having at least two structural shells, an insulating material extending therebetween, and a plurality of truss members extending therebetween. A determination is made if the two or more structural shells act as a unitary composite structural panel. If the structural panel is not a unitary composite structural panel, then parameters of the panel are adjusted and it is further determined whether the panel is a unitary composite structural panel. Combined truss systems for strengthening the structural panels may be formed by combining ladder truss members with warren truss members, by superimposing the ladder truss members and warren truss members, and by superimposing ladder truss members with a warren truss member and another warren truss member that is inverted.