Abstract: A method for producing an engineered building material comprising at least a first and second cementitious reinforced expanded honeycomb product, the method comprising: affixing at least one end of the first cementitious reinforced expanded honeycomb product to at least one end of the second cementitious reinforced expanded honeycomb product via a coupler device.

Abstract: A method for producing expanded honeycomb materials with cementitious reinforcement, in a composite structure having significant structural rigidity and strength, reduction in overall weight and ease of installation comprising the steps of: placing an expanded thermoformable honeycomb in a mold or suitable mold; partially or completely filling either or both sides of the honeycomb with cementitious material; vibrating the cementitious material within the structure to eliminate any air pockets or voids; leveling the cementitious material and allowing it to cure at room or elevated temperature; removing the composite structures from the mold.

Abstract: A method for producing an engineered building material comprising at least a first and second cementitious reinforced expanded honeycomb product, the method comprising: affixing at least one end of the first cementitious reinforced expanded honeycomb product to at least one end of the second cementitious reinforced expanded honeycomb product via a coupler device.

Abstract: A method of multiplying large integers is disclosed. Two large numbers, x and y, are provided. values are determined in accordance with the Karatsuba multiplication process based on x and y. A first and second value according to the Karatsuba multiplication method are also determined. The third value for use in accordance with the Karatsuba multiplication method is determined by determining C?=(x1+x2)[m?1:0]*(y1+y2)[m?1:0] and determining C=C?+((y1+y2)[2m:2m] AND (x1+x2)[m?1:0]+(x1+x2)[2m:2m] AND (y1+y2)[m:0])<<m, where << is a bitwise shift operation, wherein AND is performed by performing a Boolean AND of a single bit within a first operand with each bit within a second operand and wherein D[j:k] refers to the jth to kth bits of D.

Abstract: A method for continuously and cost-effectively producing expanded thermoformable honeycomb materials comprising the steps of: providing raw thermoformable thermoplastic material (such as flakes or pellets) into an extruder; heating the material in the extruder; extruding the continuous sheet material to a suitable gauge and width; trimming the extruded material while it is still hot to desired widths; conveying this hot thermoformable, continuous sheet into a preheat/heating section comprised of either hot forming rolls or belts; heating the thermoformable continuous sheet on forming rolls or between continuous forming belts that have specific geometries machined on the surfaces; adhering the continuous sheet on the forming surfaces by hot tack adhesion; expanding the continuous sheet into expanded honeycomb by separating the forming surfaces so as to effect an expansion of the cross-section of the thermoformable continuous sheet material; transferring the expanded honeycomb through an array of cooling rolls

Abstract: A method and apparatus for continuously and cost-effectively producing expanded thermoformable materials encompassing the steps of: providing raw thermoformable material into an extruder or mold; heating the material in the extruder or mold; extruding or co-extruding molding planar sheet material of suitable engineering performance parameters to a gauge and width; cutting or shearing the extruded or molded material while it is still hot to suitable lengths for expansion in a coreformer; conveying the hot thermoformable sheet material in between forming platens; heating the thermoformable material to a temperature at which the material adhesively bonds to the platens; expanding the cross-section of the thermoformable material; and then cooling the expanded thermoformable material by changing the temperature of the forming platens such that the thermoformable material can maintain its structural integrity and be released from the platens.

Abstract: A method for continuously producing high-strength welded composite panels from thermoformable material facings and expanded thermoformable material cores comprising the steps of: simultaneously feeding facing sheets and core into a welder that has automated feed rollers; heating the lower side of the top face and the upper side of the lower face simultaneously with both faces of the inner core of expanded thermoformable material; continuing to heat them to 100-400° C. until the surfaces reach the initial melt and/or hot tack temperature of the materials; pressing the heated faces together against the heated surface of the core material to consolidate the composite structure; and allowing the materials to cool while under pressure and continuing to move forward in the engaged roller mechanism until the entire panel has been welded and is dimensionally stable.