Synthetic panel and method

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a synthetic panel. More specifically, this invention provides a polymeric foamed panel (e.g. a low density synthetic panel) and method for producing the polymeric foamed panel. This invention further provides a method for forming a structure with two or more polymeric foamed panels.

2. Description of the Prior Art

A patentability investigation was conducted and the following U.S. Patents were discovered:

U.S. Pat. No. 4,163,349 to Smith; U.S. Pat. No. 4,284,447 to Dickens et al.; U.S. Pat. No. 4,602,466 to Larson; U.S. Pat. No. 4,774,794 to Grieb; U.S. Pat. No. 4,813,193 to Altizer; U.S. Pat. No. 4,856,244 to Clapp; U.S. Pat. No. 4,862,660 to Raymond; U.S. Pat. No. 4,981,003 to McCarthy; U.S. Pat. No. 5,021,108 to Bergqvist; U.S. Pat. No. 5,245,809 to Harrington; U.S. Pat. No. 5,265,389 to Mazzone et al.; U.S. Pat. No. 5,269,109 to Gulur; and U.S. Pat. No. 5,279,089 to Gulur.

U.S. Pat. No. 4,163,349 to Smith teaches an insulated building panel having a core and overlapping skins which include an interior skin and an exterior skin. The interior skin at the panel's bottom covers a panel foot plate and the exterior skin at the panel's bottom also covers the panel foot plate and extends beyond to form an erection stop. End panels have relieved core areas for receiving bearing members associated with a wall splice bearing post, and double parallel spaced header beams have an offset splice area within a several panel wall section.

U.S. Pat. No. 4,284,447 to Dickens et al. teaches a method of forming a panel structure useful in building construction and the like including the steps of heating a heat expandable plastic in a separable mold having a cavity with the configuration of the resultant panel to form a panel core and adhering thin reinforcing strips to the front and back surfaces of the core. Control over the dimensions and configuration of the panel to Dickens et al. is obtained by adhering the strips to the core in the mold while applying heat thereto whereby core shrinkage is minimized.

U.S. Pat. No. 4,602,466 to Larson teaches a method and apparatus for making building panels, including a means for positioning upper and lower rigid sheets of material, such as paper pulp, in spaced relation so that foamable material disposed between the sheets can move into gripping engagement with both sheets as it expands and solidifies.

U.S. Pat. No. 4,774,794 to Grieb teaches a foam-cement building having the walls, roof and/or floor formed from a plurality of self supporting foam building blocks of varying density with a strong thin continuous structural and architectural coating on the surface of the blocks. The coating is formed from cement, reinforced with a fiberglass mesh and fiberglass roving strands. The blocks are interconnected by a mechanical key system or splines to form a monolithic structure.

U.S. Pat. No. 4,813,193 to Altizer teaches an improved modular building comprising sidewall modules and ceiling modules. The sidewall modules comprise a primary frame to which a secondary frame of furring strips is attached. The sidewall modules further comprise foam insulation molded around the primary and secondary frame to define exterior and interior planar surfaces. The ceiling modules include frame means supporting a plurality of ceiling joists, and foam insulation dispersed within the frame means and between the ceiling joist so as to define upper and lower ceiling surfaces.

U.S. Pat. No. 4,856,244 to Clapp teaches tilt-wall concrete panels adapted for constructing small buildings with “finished” interiors, especially single-family residences, etc. A peripheral frame of wooden members is laid on top of a barrier film of plastic (e.g. 4 mil polyethylene) on a horizontal surface. Wood-like studs are then placed within the frame and nailed thereto. Any desired utility cables and service pipes are positioned within the frame. Clapp further teaches that an insulating foam cover, preferably high-density polyurethane, is then generated within and over the frame, to a depth that at least covers the wood-like studs and any utility or service lines. Foam having a thickness of about 1.5 inches covers these elements and bonds them securely together as a stable, easily movable “plate” after the foam plastic has hardened. A plurality of such plates, each sized to form a part of a building's wall, are positioned at a construction site where a foundation has been prepared. Clapp discloses that a concrete form is then temporarily completed around each plate, and concrete is poured on top thereof, to an average depth of about 4 to 6 inches. After the concrete hardens, the temporary form is removed and the composite panel is tilted to a vertical position. A plurality of such panels by Clapp are positioned edge-to-edge and joined to form a continuous outer wall for the building. The plastic barrier film is removed from the face of each panel, and interior wallboards or the like may be nailed to the exposed wood-like studs.

U.S. Pat. No. 4,862,660 to Raymond teaches an integral energy efficient load-bearing exterior wall fabricated of lightweight foam surrounding plastic load-bearing columns. Raymond discloses prefabricated modular wall panels as individual building elements and as part of an integrated building system. The prefabricated modular wall panels are made from a foamed material that is molded around a plurality of vertically disposed hollow support columns. Each of the columns in U.S. Pat. No. 4,862,660 to Raymond is taught as containing a pair of opposed and vertically disposed T-shaped fastening supports which are arranged to form part of the interior and exterior surfaces of the foamed wall. The hollow columns are set onto locking base plates which are mounted on a wood or concrete deck system. Locking top plates are also mounted on wood and are then placed on top of the columns. The tubular columns are made of a plastic material and are shaped in cross-section in the form of a rectangle, square, diamond, oval or circle.

U.S. Pat. No. 4,981,003 to McCarthy teaches a wall panel constructed from expanded polystyrene beads in an expanded polystyrene mold with structural members embedded in it during the molding process. The structural members are in the form of two by four studs placed at sixteen inch centers. Adjacent panels have interlocking grooves and ridges which fit together. McCarthy teaches that an advantage of his invention is that a total insulated wall is created with no cracks or spaces in the insulation.

U.S. Pat. No. 5,021,108 to Bergqvist teaches an apparatus for manufacture of laminated panels having a foamed plastic core material including an inclined press having a fixed platen surface and a movable platen surface hinged adjacent to its lower edge. Panel thickness is adjustable by a mechanism which moves the hinge pivot relative to fixed platen surfaces. The platen surfaces in U.S. Pat. No. 5,021,108 to Bergqvist are clamped at their upper edges by spaced clamps operable by lever and crank assemblies. A retractable seal spacer has liquid plastic injection nozzles and gas venting tubes in fluid communication with a hollow cavity in the press.

U.S. Pat. No. 5,245,809 to Harrington teaches a panel for providing walls, roofs and floors with thermal insulation and fire retardance. The panel is taught to comprise at least two essentially parallel face members separated to form a space between the face members and urethane within the space to provide the thermal insulation and fire retardance. The panel may additionally include frame members extending between the face members for providing support and for enclosing the urethane. At least one of the frame members has at least one port through which urethane foam can enter between the face members. U.S. Pat. No. 5,245,809 to Harrington further teaches a method for creating a panel for providing insulated and fire retardant walls, floors and roofs. The method is taught by Harrington to include the steps of joining frame members together to form a panel frame of the desired dimensions, attaching face members to either side of the panel frame so that at least one enclosed space is formed within the face members and frame members, creating at least one port leading into the at least one enclosed space, and injecting urethane foam through the at least one port into the at least one enclosed space.

U.S. Pat. No. 5,265,389 to Mazzone et al. teaches a composite building panel including a core of a foamed polymeric insulating material, such as expanded polystyrene, having a plurality of uniformly spaced open box tubes retained in vertical grooves formed in the rear surface of the core by a two-part epoxy adhesive. The tubes are mechanically connected at their ends to one leg of continuous horizontal channels having their other leg adhesively secured to the core at horizontal slots. The front surface of the core is continuous without seams and may be coated with a variety of exterior insulation finishing system coatings.

U.S. Pat. Nos. 5,269,109 and 5,279,089 to Gulur teach an insulated load bearing wall comprising panels of extruded polymer foam into which tubular, load carrying frame members have been incorporated. A tongue is formed at one vertical edge of each panel and a groove is formed at the opposite vertical edge. The tubular frame members are bonded to the extruded polymer foam.

None of the foregoing U.S. Patents teach the particular methods of the present inventions for producing panels having a core of a foamed polymeric material, such as expanded polystyrene. StressSkin and Structural Panels have been in use for several decades. Alden Dow constructed his first StressSkin panel house in the late forties. Both technologies have relied on an inner and outer skin of wood either being plywood or more recently OSB (oriented strand board). The plywood or OSB skin is attached to the foam core with an adhesive and then pressed together. The laminated panels are thereafter processed into engineered parts. The plywood or OSB skin does not provide for both a structure and a substrate for the interior and exterior finishes. Thus, what is needed and what has been invented by us is a foamed wall system and method that provides for a foamed polymeric material that becomes both a structure and a substrate for the interior and exterior finishes.

SUMMARY OF THE INVENTION

The present invention accomplishes its desired objects by providing a method for producing a polymeric foamed material panel (e.g. a low density synthetic panel) comprising the steps of:

(a) providing a polymeric foamed material;

(b) cutting the polymeric foamed material of step (a) until reaching a preconfiguration cut point;

(c) cutting subsequently from the preconfiguration cut point a brace-receiving configuration in the polymeric foamed material; and

(d) sliding a brace member into the brace-receiving configuration to produce a polymeric foamed material panel.

The cutting in step (b) and the cutting in step (c) comprises cutting the polymeric foamed material of step (a) with a hot wire cutter which is preferably operated by a computer. The brace-receiving configuration in the polymeric foamed material comprises a slot for receiving the brace member. The slot includes a seared wall for facilitating the sliding of the brace member. The brace member includes an opening with an opening perimeter. The method additionally comprises forming a polymeric foamed material opening in the polymeric foamed material. The polymeric foamed material opening has a polymeric foamed material opening perimeter. The sliding in step (d) comprises sliding the brace member into the brace-receiving configuration until the opening of the brace member is generally aligned with the polymeric foamed material opening. The opening perimeter of the opening in the brace member has a dimension that is greater than a dimension of the polymeric foamed material opening perimeter of the polymeric foamed material opening in the polymeric foamed material.

The method preferably additionally comprises passing a conduit through the polymeric foamed material opening of the polymeric foamed material and through the opening of the brace member; preferably such that the conduit is essentially supported by the polymeric foamed material and essentially does not contact any of the opening perimeter of the opening in the brace member. The cutting in step (b) further comprises cutting a generally straight thread-like slot from a defined surface of the polymeric foamed material to the preconfiguration cut point. The brace-receiving configuration is essentially a generally C-shaped slot. The method further preferably includes that the cutting in step (b) and the cutting in step (c) is with a hot wire cutter wherein the hot wire cutter is at a temperature (e.g. 230° F. to 580° F.) such as to sear at least one wall of the C-shaped slot to smooth and harden the wall of the C-shaped slot for facilitating the sliding in step (d) of the brace member. The polymeric foamed material may be any suitable material (i.e. either low density and/or high density including engineered resins) that is capable of producing the panel or structure of the present invention, such as expanded polystyrene (EPS).

The present invention further accomplishes its desired objects by providing a method for forming a structure comprising the steps of:

(a) providing a first polymeric foamed material having a first defined edge;

(b) cutting the first polymeric foamed material until receiving a first preconfiguration cut point and cutting subsequently from the first preconfiguration cut points a first brace-receiving-configured slot in the first polymeric foamed material;

(c) cutting the first defined edge of the first polymeric foamed material to form a tongue on the first defined edge;

(d) sliding a first brace member into the first brace-receiving-configured slot;

(e) providing a second polymeric foamed material having a second defined edge;

(f) cutting the second polymeric foamed material until reaching a second preconfiguration cut point and cutting subsequently from the second preconfiguration cut point a second brace-receiving-configured slot in the second polymeric foamed material;

(g) cutting the second defined edge of the second polymeric foamed material to form a channel in the second defined edge;

(h) sliding a second brace member into the second brace-receiving-configured slot; and

(i) sliding the tongue on the first defined edge of the first polymeric foamed material into the channel in the second defined edge of the second polymeric foamed material to form a structure.

The cutting in steps (b), (c), (f) and (g) comprises cutting with a hot wire cutter; preferably a computer operated hot wire cutter. The first brace-receiving-configured slot in the first polymeric foamed material and the second brace-receiving-configured slot in the second polymeric foamed material respectively comprise a first slot with a first wall for receiving the first brace member and a second slot with a second wall for receiving the second brace member. The first wall of the first slot includes a first seared wall for facilitating the sliding of the first brace member and the second wall of the second slot includes a second seared wall for facilitating the sliding of the second brace member. The first brace member includes a first opening with a first opening perimeter and the second brace member includes a second opening with a second opening perimeter.

The method additionally includes forming a first polymeric foamed material opening in the first polymeric foamed material and forming a second polymeric foamed material opening in the second polymeric foamed material. The first polymeric foamed material opening includes a first polymeric foamed material opening perimeter and the second polymeric foamed material opening includes a second polymeric foamed material opening perimeter. The sliding step (d) comprises sliding the first brace member into the first brace-receiving-configured slot until the first opening of the first brace member is generally aligned with the first polymeric foamed materials opening; and the sliding step (h) comprises sliding the second brace member into the second brace-receiving-configured slot until the second opening of the second brace member is generally aligned with the second polymeric foamed material opening. The first and second openings of the first and second brace members and the first and second polymeric foamed material openings of the first and second polymeric foamed materials are all aligned for receiving a conduit. The first opening perimeter of the first opening in the first brace member has a first dimension that is greater than a first dimension of the first polymeric foamed material opening perimeter of the first polymeric foamed material opening in the first polymeric foamed material; and the second opening perimeter of the second opening in the second-brace member has a second dimension that is greater than a second dimension of the second polymeric foamed material opening perimeter of the second polymeric foamed material opening in the second polymeric foamed material.

The method preferably additionally comprises passing a conduit through the first polymeric foamed material opening in the first polymeric foamed material and through the first opening of the first brace member and further passing the conduit through the second polymeric foamed material opening in the second polymeric material and through the second opening of the second brace member; preferably such that the conduit is essentially supported by the first polymeric foamed material and by the second polymeric material and essentially does not contact any of the first opening perimeter of the first opening in the first brace member and any of the second opening perimeter of the second opening in the second brace member.

The method also preferably additionally comprises cutting, prior to the cutting in step (b), a first generally straight thread-like slot in the first polymeric foamed material up to a first preconfiguration cut point wherein the step (b) cutting commences; and further also preferably additionally comprises cutting, prior to the cutting in step (f), a second generally straight thread-like slot in the second polymeric foamed material up to a second preconfiguration cut point wherein the step (f) cutting commences. The first brace-receiving-configured slot is essentially a first generally C-shaped slot and the second brace-receiving-configured slot is essentially a second generally C-shaped slot. The cutting in step (b), step (c), step (f), and step (g) comprises cutting with a hot wire cutter which is at a temperature (e.g. 230° F. to 580° F.) such as to sear at least one wall of the first C-shaped slot and to sear at least one wall of the second C-shaped slot to smooth and harden the wall of the first C-shaped slot and to smooth and harden the wall of the second C-shaped slot for facilitating the sliding in step (d) of the first brace member and for facilitating the sliding in step (h) of the second brace member. The first polymeric foamed material and the second polymeric foamed material both may consist of any suitable material (e.g. any suitable polymeric foamed material) such as that comprising expanded polystyrene (EPS).

The present invention therefore provides a method for producing a polymeric foamed material panel comprising the steps of:

(a) providing a polymeric foamed material in a generally stationary position;

(b) cutting the generally stationary polymeric foamed material of step (a) until reaching a preconfiguration cut point;

(c) cutting subsequently from the preconfiguration cut point a brace-receiving configuration in the generally stationary polymeric foamed material; and

(d) sliding a brace member into the brace-receiving configuration to produce a polymeric foamed material panel.

The present invention further therefore provides a method for producing a polymeric foamed material panel comprising the steps of:

(a) providing a polymeric foamed material;

(b) providing a brace member with brace sides;

(c) cutting a brace-receiving configuration in the polymeric foamed material; and

(d) sliding the brace member of step (b) into the brace-receiving configuration such that the brace sides are essentially surrounded by the polymeric foamed material to produce a polymeric foamed material panel.

The present invention also further therefore provides a method for producing a polymeric foamed material panel comprising the steps of:

(a) providing a polymeric foamed material with a planar side surface;

(b) cutting with a cutter from the planar side surface a path in the polymeric foamed material of step (a);

(c) retracing the path of step (b) with the cutter to produce a brace-receiving configuration in the polymeric foamed material; and

(d) sliding a brace member into the brace-receiving configuration to produce a polymeric foamed material panel.

The present invention yet also further therefore provides a method for producing a polymeric foamed material panel comprising the steps of:

(a) providing a polymeric foamed material with a planar side surface;

(b) contacting the planar side surface with a cutter;

(c) cutting with the cutter the polymeric foamed material from the planar side surface thereof until reaching a preconfiguration cut point within the polymeric foamed material;

(d) cutting with the cutter from the preconfiguration cut point of step (c) a slot in the polymeric foamed material of step (c);

(e) cleaning the slot of step (d) with the cutter to produce a brace-receiving configuration in the polymeric foamed material; and

(f) sliding a brace member into the brace-receiving configuration to produce a polymeric foamed material panel.

In addition to the foregoing methods, the present invention provides at least one polymeric foamed material panel. The polymeric foamed material panel of the present invention comprises a panel consisting of a polymeric foamed material. A brace-receiving-configured slot is disposed in the polymeric foamed material of the panel and a brace member is disposed in the brace-receiving-configured slot in the polymeric foamed material of the panel. The brace-receiving-configured slot preferably includes at least one seared wall; and the polymeric foamed material panel additionally comprises a generally straight thread-like slot extending from a defined surface of the polymeric foamed material to the brace-receiving-configured slot; and a second generally straight thread-like slot extending from the defined surface of the polymeric foamed material to a generally cylindrical opening in the polymeric foamed material. The brace member has a brace opening which is generally aligned with the cylindrical opening in polymeric foamed material.

In another embodiment of the present invention there is provided a method for forming a structure comprising the steps of:

(a) providing a first polymeric foamed material having a first defined edge;

(b) cutting (e.g. with a hot wire cutter or a laser cutter) a first slot in the first polymeric foamed material;

(c) providing a first internal reinforcing member having a male member;

(d) sliding the first internal reinforcing member of step (c) into the first slot of step (b) such that the male member protrudes from the first defined edge;

(e) providing a second polymeric foamed material having a second defined edge;

(f) cutting (e.g. with a hot wire cutter or a laser cutter) a second slot in the second polymeric foamed material;

(g) providing a second internal reinforcing member having a female member;

(h) sliding the second internal reinforcing member of step (g) into the second slot of step (f) such that the female member is exposed along the second defined edge; and

(i) sliding the male member, which projects from the first defined edge of the first polymeric foamed material, into the female member, which is exposed along the second defined edge of the second polymeric foamed material, to form a structure.

In yet another embodiment of the present invention, there is provided a method for producing a plurality of polymeric foamed material structures having brace-receiving configurations comprising the steps of:

(a) providing a block, preferably a generally stationary block, of polymeric foamed material, such as expanded polystyrene (EPS);

(b) cutting the polymeric foamed material of step (a) with a plurality of cutters (e.g., hot wire cutters, laser cutters, etc.) until each cutter reaches a respective preconfiguration cut point;

(c) cutting subsequently with each cutter from the respective preconfiguration cut point of each cutter a respective brace-receiving configuration in the polymeric foamed material; and

(d) cutting, after the cutting step (c), the polymeric foamed material of step (c) with the plurality of cutters to produce a plurality of polymeric foamed material structures, each of the polymeric foamed material structures having a brace-receiving configuration, which may be linear or nonlinear.

The immediate foregoing method additionally comprises cutting with each cutter, prior to the cutting step (d), a respective polymeric foamed material opening in the polymeric foamed material such that each polymeric foamed material structure has a polymeric foamed material opening to define a chase. The cutters are preferably computer operated to provide desired cut accuracy.

In yet another embodiment of the present invention, there is also provided a method for producing a plurality of polymeric foamed material panels comprising the steps of:

(a) providing a block (e.g., a generally stationary block) of polymeric foamed material (e.g., expanded polystyrene (EPS));

(b) cutting the polymeric foamed material of step (a) with a plurality of cutters (e.g., hot wire cutters, laser cutter, etc.) until each cutter reaches a respective preconfiguration cut point;

(c) cutting subsequently with each cutter from the respective preconfiguration cut point of each cutter a respective brace-receiving slot in the polymeric foamed material;

(d) cutting, after the cutting step (c), the polymeric foamed material of step (c) with said plurality of cutters to produce a plurality of polymeric foamed material structures having a plurality of brace-receiving slots, which may be linear or nonlinear slots; and

(e) sliding a plurality of brace members into the brace-receiving slots of the polymeric foamed material structures of step (d) to produce a plurality of polymeric foamed material panels, each of the polymeric foamed material panels having at least one of the brace members.

In the immediate foregoing method of the present invention, the brace members include sides. More particularly, each of the brace members preferably comprises a web, a first flange integrally bound to the web, a first flange return integrally bound to the first flange, a second flange also integrally bound to the web, and a second flange return integrally bound to the second flange. The web, the first and second flanges, and the first and second flange returns are surrounded by the polymeric foamed materials. Alternatively and as another embodiment of the present invention, a portion of at least one brace member protrudes from each of the polymeric foamed material panels. Therefore, the sliding step (e) in the immediate foregoing method more specifically comprises sliding the first flange and the first flange return and a portion of the web of respective brace members into respective brace-receiving slots of the polymeric foamed material structures to produce the plurality of polymeric foamed material panels, with each of the polymeric foamed material panels having the second flange and the second flange return and a portion of the web of at least one of the brace members disposed outside thereof.

An alternative embodiment of the present invention further also provides a method for producing a plurality of polymeric foamed material structures having slots for receiving stud members comprising the steps of:

(a) cutting a polymeric foamed material (e.g., a generally stationary block of expanded polystyrene (EPS)) with a plurality of cutters, such as hot wire cutters or laser cutters, in a first direction;

(b) cutting subsequently in a second direction the polymeric foamed material of step (a) with the plurality of cutters until each cutter forms a first respective slot in the polymeric foamed material;

(c) cutting, after the cutting step (b), in the first direction the polymeric foamed material of step (b) with the plurality of cutters to produce a plurality of polymeric foamed material structures having a plurality of first slots, which may be linear or nonlinear slots.

The immediately foregoing method broadly additionally comprises cutting, prior to the cutting step (c), the polymeric foamed material of step (b) with the plurality of cutters until each cutter forms a second respective slot in the polymeric foamed material. The immediate foregoing method more particularly additionally comprises cutting, prior to the cutting step (c), the polymeric foamed material of step (b) with the plurality of cutters until each cutter forms a respective recess in the polymeric foamed material; and subsequently cutting, prior to the cutting step (c), the polymeric foamed material with the plurality of cutters until each cutter forms a second respective slot in the polymeric foamed material such that after the cutting step (c), a plurality of polymeric foamed material structures are produced having a plurality of first slots and a plurality of second slots and a plurality of recesses. A plurality of stud members is provided wherein each of the stud members comprises a web, a first flange integrally bound to the web, a first flange return integrally bound to the first flange, a second flange also integrally bound to the web, and a second flange return integrally bound to the second flange. The stud members are slid into the first and second slots and into the recesses of the polymeric foamed material structures, such that after the sliding step, the first flange return and the first flange of each of the stud members occupies respectively one of the first slots and one of the recesses of the polymeric foamed material structures, and the web, the second flange and the second flange return of each of the stud members occupies one of the second slots of the polymeric foamed material structures. The cutters are preferably computer operated to provide the desired cut accuracy during the cutting steps.

The alternative embodiment of the present invention more specifically includes a method for producing a plurality of polymeric foamed material structures having slots for receiving stud members comprising the steps of:

(a) cutting a polymeric foamed material with a plurality of cutters in a first direction until each of the cutters has moved a respective first distance in the polymeric foamed material;

(b) cutting subsequently with the plurality of cutters in a second direction the polymeric foamed material of step (a) until each of the cutters has moved a respective second distance in the polymeric foamed material of step (a);

(c) cutting subsequently with the plurality of cutters in the first direction the polymeric foamed material of step (b) until each of the cutters has moved a respective third distance in the polymeric foamed material of step (b);

(d) cutting subsequently with the plurality of cutters in a third direction the polymeric foamed material of step (c) until each of the cutters has moved a respective fourth distance in the polymeric foamed material of step (c);

(e) cutting subsequently with the plurality of cutters in the first direction the polymeric foamed material of step (d) until each of the cutters has moved a respective fifth distance in the polymeric foamed material of step (d);

(f) cutting subsequently with the plurality of cutters in the second direction the polymeric foamed material of step (e) until each of the cutters has moved a respective sixth distance in the polymeric foamed material of step (e);

(g) cutting subsequently with the plurality of cutters in a fourth direction the polymeric foamed material of step (f) until each of the cutters has moved a respective seventh distance in the polymeric foamed material of step (f);

(h) cutting subsequently with the plurality of cutters in the third direction the polymeric foamed material of step (g) until each of the cutters has moved a respective eighth distance in the polymeric foamed material of step (g);

(i) cutting subsequently with the plurality of cutters in the fourth direction the polymeric foamed material of step (h) until each of the cutters has moved a respective ninth distance in the polymeric foamed material of step (h);

(j) cutting subsequently with the plurality of cutters in the second direction the polymeric foamed material of step (i) until each of the cutters has moved a respective tenth distance in the polymeric foamed material of step (i);

(k) cutting subsequently with the plurality of cutters in the first direction the polymeric foamed material of step (j) until each of the cutters has moved a respective eleventh distance in the polymeric foamed material of step (j);

(l) cutting subsequently with the plurality of cutters in the third direction the polymeric foamed material of step (k) until each of the cutters has moved a respective twelfth distance in the polymeric foamed material of step (k); and

(m) cutting, after the cutting step (l), in the first direction the polymeric foamed material of step (l) with the plurality of cutters to produce a plurality of polymeric foamed material structures having a plurality of slots.

In the immediate foregoing method, the respective third distance and the respective eighth distance are approximately equal. Similarly, the respective fifth distance and the respective seventh distance are approximately equal. The respective fourth distance is generally less than the respective second distance, and the respective eighth distance is generally less than the respective tenth distance. The third direction is generally opposite to the second direction, and the fourth direction is generally opposite to the first direction. The cutters are preferably computer operated hot wire cutters which generally move in unison. Each of the hot wire cutters includes a wire diameter with a generally known diameter measurement which generally equals the respective third distance and the respective eighth distance.

One of the alternative embodiments of the present invention also more specifically includes a method for producing a plurality of polymeric foamed material structures comprising the steps of:

(a) cutting a polymeric foamed material (e.g., a generally stationary block of expanded polystyrene (EPS)) with a plurality of cutters (e.g., computer-operated hot wire cutters or laser cutters) until each cutter reaches a respective first cut point;

(b) cutting subsequently with each cutter from the respective first cut point a respective path in the polymeric foamed material of step (a) until each cutter reaches a respective second cut point;

(c) moving each of the plurality of cutters from the respective second cut point to a respective off-set position in the polymeric foamed material of step (b);

(d) retracing generally with each cutter the respective path of each cutter, while each cutter remains in the respective off-set position of step (c) such that a respective slot is formed by each cutter in the polymeric foamed material of step (c); and

(e) cutting the polymeric foamed material of step (d) with the plurality of cutters until the cutters have cut through the polymeric foamed material of step (d), producing a plurality of polymeric foamed material structures having slots, which may be either linear or non-linear slots. The method additionally comprises cutting with the plurality of cutters track chases in the polymeric foamed material structures of step (e) such that each of the plurality of polymeric foamed material structures additionally includes a track chase.

Other features of the alternative embodiments of the present invention include interrupting the movement of a plurality of cutters in a first direction of travel to move the cutters in at least one direction of travel which differs from the first direction of travel in order to form one or more brace-receiving slots. These features are embodied in a method for producing a plurality of polymeric foamed material structures having brace-receiving slots comprising the steps of: (a) providing a block of polymeric foamed material; and (b) moving a plurality of cutters through the block of polymeric foamed material in a first direction of travel, while interrupting at least one time the moving of the plurality of cutters in the first direction of travel to move the cutters through the block of polymeric foamed material in at least one direction of travel which differs from the first direction of travel, such that each cutter produces a respective brace-receiving slot in the polymeric foamed material, until the plurality of cutters have moved completely through the block of polymeric foamed material to produce a plurality of polymeric foamed material structures with each structure having at least one brace-receiving slot. These features are also embodied in a method for producing a plurality of polymeric foamed material structures having brace-receiving slots comprising the steps of: (a) providing a block of polymeric foamed material in a generally stationary position; (b) moving a plurality of cutters through the generally stationary block of polymeric foamed material of step (a) in a first direction of travel; (c) interrupting the movement of the plurality of cutters from the first direction of travel through the generally stationary block of polymeric foamed material to move the cutters in at least one direction of travel which differs from the first direction of travel such that each cutter produces a respective brace-receiving slot in the polymeric foamed material, and (d) continuing the moving step (b) of the plurality of cutters in the first direction of travel, while intermittently interrupting the movement of the plurality of cutters from the first direction of travel to move the cutters in at least one direction of travel which differs from the first direction of travel such that each cutter produces at least one additional respective brace-receiving slot in the polymeric foamed material, until the plurality of cutters have moved completely through the generally stationary block of polymeric foamed material after which a plurality of polymeric foamed material structures are produced with each polymeric foamed material structure having a plurality of brace-receiving slots.

An alternative embodiment of the present invention therefore accomplishes its desired objects by broadly providing a method for producing a plurality of polymeric foamed material panels comprising the steps of:

(a) cutting a polymeric foamed material in a first direction with a plurality of cutters generally moving in unison;

(b) cutting subsequently the polymeric foamed material of step (a) in a second direction with the plurality of cutters generally moving in unison;

(c) cutting, after the cutting step (b), the polymeric foamed material of step (b) in the first direction with the plurality of cutters generally moving in unison;

(d) cutting, after the cutting step (c), the polymeric foamed material of step (c) in a third direction with the plurality of cutters generally moving in unison wherein the third direction is generally opposite to the second direction;

(e) cutting, after the cutting step (d), the polymeric foamed material of step (d) in the first direction with the plurality of cutters generally moving in unison until the cutters have cut through the polymeric foamed material of step (d) to produce a plurality of polymeric foamed material structures having brace-receiving configurations; and

(f) sliding brace members into the brace-receiving configurations of the polymeric foamed material structures of step (e) to produce a plurality of polymeric foamed material panels with each polymeric foamed material panel having one of the brace members.

An alternative embodiment of the present invention also accomplishes its desired objects by broadly providing a method for producing a polymeric foamed material structure having a slot comprising the steps of:

(a) cutting with a cutter a polymeric foamed material until reaching a preslot cut point;

(b) cutting subsequently a first path in the polymeric foamed material with the cutter from the preslot cut point until reaching a first cut point;

(c) moving the cutter in the polymeric foamed material of step (b) a predetermined distance from the first cut point to a second cut point; and

(d) cutting subsequently from the second cut point a second path in the polymeric foamed material of step (c) with the cutter until the cutter reaches a postslot cut point to produce a polymeric foamed material structure having a slot.

In the immediate foregoing method of the present invention, the cutter is preferably a computer-operated hot wire cutter having a wire diameter with a generally known diameter measurement, and the slot of step (d) has a width equal to about twice the generally known diameter measurement of the wire diameter, and a width equal to about twice the predetermined distance of step (c). A stud member may be slid into the slot of step (d).

An alternative embodiment of the present invention further also accomplishes its desired objects by broadly providing a method for producing at least one polymeric foamed material structure having at least one slot comprising the steps of:

(a) providing at least one cutter;

(b) cutting with the cutter of step (a) a polymeric foamed material until the cutter reaches at least one respective preslot cut point;

(c) cutting subsequently with cutter from the respective preslot cut point of step (b) at least one respective path in the polymeric foamed material of step (b) until the cutter reaches at least one first cut point;

(d) forming with the cutter in the polymeric foamed material of step (c) at least one respective offset path communicating with the respective path of step (c) to form at least one slot within the polymeric foamed material of step (c); and

(e) cutting subsequently the polymeric foamed material of step (d) with the cutter until the cutter has cut through the polymeric foamed material of step (d), producing at least one polymeric foamed structure having at least one slot.

In the immediate foregoing method for an improved embodiment of the present invention, the at least one respective path has at least one respective path length, and the at least one respective off-set path communicates with the at least one respective path along the at least one respective path length of the at least one respective path, such that the at least one respective path and the least one respective off-set path together form the at least one slot within the polymeric foamed material of step (c). Preferably, the at least one cutter comprises a plurality of computer-operated hot wire cutters cutting a plurality of respective paths in the polymeric foamed material of step (b) and forming a plurality of respective off-set paths in the polymeric foamed material of step (c), such that the plurality of respective paths and the plurality of respective off-set paths together form a plurality of respective slots in the polymeric foamed material of step (c), and such that, after the cutting step (e) with the plurality of hot wire cutters, a plurality of polymeric foamed structures are produced having a plurality of slots. A plurality of stud members are slid into the plurality of slots.

Another embodiment of the present invention provides method for producing a plurality of polymeric foamed material structures having seared surfaces for contacting brace members comprising the steps of:

a) providing a block of polymeric foamed material which is preferably stationary, having a side and a pair of opposed ends;

b) cutting the block of polymeric foamed material with a plurality of hot wire cutters, which is preferably computer-operate in a first direction generally perpendicular from the side of the block of polymeric foamed material;

c) cutting, immediately after said cutting step (b), the block of polymeric foamed material with the plurality of hot wire cutters in a second direction generally perpendicular from the first direction until each hot wire cutter forms in the polymeric foamed material a first respective cut seared surface terminating in the opposed ends of the block of polymeric foamed material;

d) cutting, immediately after said cutting step (c), the block of polymeric foamed material with the plurality of hot wire cutters in a third direction generally perpendicular from the second direction until each hot wire cutter form in the polymeric foamed material a second respective cut seared surface terminating in the opposed ends of the block of the polymeric foamed material;

e) cutting the block of polymeric foamed material with the plurality of hot wire cutters in a fourth direction until each hot wire cutter forms in the polymeric foamed material a third respective cut seared surface terminating in the opposed ends of the block of polymeric foamed material;

f) cutting the block of polymeric foamed material with the plurality of hot wire cutters in a fifth direction, which may be generally perpendicular from the fourth direction, until each hot wire cutter forms in the polymeric foamed material a fourth respective cut seared surface terminating in the opposed ends of the block of polymeric foamed material; and

g) cutting the block of polymeric foamed material with the plurality of hot wire cutters in a sixth direction, which may be generally perpendicular from the fifth direction, to produce a plurality of polymeric foamed material structures, each of the polymeric foamed material structures having a first cut seared surface and a second cut secured surface for contacting a first brace member and a third cut seared surface and a fourth cut seared surface for contacting a second brace member.

The immediate foregoing method may additionally comprise cutting the block of polymeric foamed material with the plurality of hot wire cutters between the cutting step (d) and the cutting step (e). Also, the method may additionally comprise cutting the block of polymeric foamed material with the plurality of hot wire cutters such the each of the polymeric foamed material structures has a tongue member and a channel member. The cutting step (f) may be before or after the cutting step (e).

Preferably, the cutting step (g) is after the cutting step (f). The cutting step (c) additionally produces an opposed first respective cut seared surface terminating in the opposed ends of the block of polymeric foamed material and opposed to the first respective cut seared surface to form a first slot in each of the polymeric foamed material structures; and the cutting step (d) additionally produces an opposed second respective cut seared surface terminating in the opposed ends of the block of polymeric foamed material and opposed to the second respective cut seared surface to form a second slot in each of the polymeric foamed material structures, each of the polymeric foamed material structures having the first slot and the second slot for receiving a first brace member, and the cutting step (e) additionally produces an opposed third respective cut scared surface terminating in the opposed ends of the block of polymeric foamed material and opposed to the third respective cut seared surface to form a third slot in each of the polymeric foamed material structures; and the cutting step (f) additionally producing an opposed fourth respective cut seared surface terminating in the opposed ends of the block of polymeric foamed material and opposed the fourth respective cut seared surface to form a fourth slot in each of the polymeric foamed material structures, each of the polymeric foamed material structures having the third slot and the fourth slot for receiving a second brace member.

The immediate foregoing method more specifically additionally comprises forming a first flange-return slot, a second flange-return slot, a third flange-return slot, and a fourth flange-return slot in each of the polymeric foamed material structures. The method more specifically firer additionally comprises providing a plurality of first brace members wherein each of the first brace members comprises a first web, a first flange secured to the first web, a first flange return secured to the first flange, a second flange secured to the web, and a second flange return secured to said second flange; and additionally comprising providing a plurality of second brace members wherein each of the second brace members comprises a second web, a third flange secured to the second web, a third flange return secured to the third flange, a fourth flange secured to the second web, a fourth flange return secured to the fourth flange. The plurality of the first brace members and the plurality of the second brace members are preferably disposed in the plurality of polymeric foamed material structures such that each of the polymeric foamed material structures comprises the first web of the first brace member positioned against the first cut seared surface, the first flange positioned against the second cut secured surface, the first flange return positioned in the first flange-return slot, the second flange return positioned in the second flange-return slot, the second web of the second brace member positioned against the fourth cut seared surface, the third flange positioned against the third cut seared surface, the third flange return positioned in the third flange-return slot, and the fourth flange return positioned in the fourth flange-return slot. The block of polymeric foamed material may be cut prior to the cutting step (g) or after the cutting step (g) and/or prior to disposing the plurality of the first brace members and the plurality of the second brace members in the plurality of polymeric foamed material structures. Embodiments of the present inventions include one or more polymeric foamed material structures, including one or more produced in accordance with any of the methods of the embodiments of the present invention.

Further embodiments of the present invention include a method for forming a structure comprising the steps of:

a) cutting a first polymeric foamed material with a first cutter (e.g., a hot wire cutter or laser cutter) in a first direction relative to a first side surface of the first polymeric foamed material;

b) cutting with the first cutter the first polymeric foamed material in a second direction relative to the first direction to produce a first-cutter first cut surface terminating in opposed ends of the first polymeric foamed material;

c) cutting with the first cutter the first polymeric foamed material in a third direction relative to the second direction to produce a first-cutter second cut surface terminating in the opposed ends of the first polymeric foamed material

d) cutting the first polymeric foamed material with the first cutter to produce a first tongue in the first polymeric foamed material;

e) providing a first brace member having a first web and at least one first flange secured to the first web;

f) disposing respectively the first web and the first flange of the first brace member against the first-cutter first cut surface of step (b) and the first-cutter second cut surface of step (c) to produce a first polymeric foamed material panel having the first tongue;

g) cutting a second polymeric foamed material with a second cutter (e.g., a hot wire cutter or a laser cutter) to produce a second channel in the second polymeric foamed material;

h) cutting the second polymeric foamed material with the second cutter in a first direction relative to a second side surface of the second polymeric foamed material;

i) cutting with the second cutter the second polymeric foamed material in a second direction relative to the first direction to produce a second-cutter first cut surface terminating in opposed ends of the second polymeric foamed material;

j) cutting with the second cutter the second polymeric foamed material in a third direction relative to the second direction to produce a second-cutter second cut surface terminating in the opposed ends of the second polymeric foamed material;

k) providing a second brace member having a second web and at least one second flange secured to the second web;

l) disposing respectively the second web and the second flange of the second brace member against the second-cutter first cut surface of step (i) and the second-cutter second cut surface of step (j) to produce a second polymeric foamed material panel having the second channel; and

m) sliding the first tongue of the first polymeric foamed material panel into the second channel of the second polymeric foamed material panel to form a structure.

The immediate foregoing method preferably additionally comprises cutting the first polymeric foamed material with the first cutter to produce a first channel in the polymeric foamed material and cutting the second polymeric foamed material with the second cutter to produce a second tongue in the second polymeric foamed material. The first direction of step (a) is preferably generally perpendicular to the first side surface of step (a), and the second direction of step (b) is preferably generally perpendicular to the first direction of step (a). The third direction step (c) is preferably generally perpendicular to the second direction of step (b). The first direction of step (h) is preferably generally perpendicular to the second side surface of step (h), the second direction of step (i) is preferably generally perpendicular to the first direction of step (h), and the third direction of step (j) is preferably generally perpendicular to the second direction of step (i). The method additionally comprises cutting respectively the first polymeric foamed material with the first cutter in the cutting steps (a) through (d) generally simultaneously with cutting respectively the second polymeric foamed material with the second cutter in the cutting steps (g) through (j). The cutting step (b) preferably additionally produces an opposed first-cutter first cut surface terminating in the opposed ends of the first polymeric foamed material and opposed to the first-cutter first cut surface to form a first-cutter first slot in the first polymeric foamed material; and the cutting step (c) preferably additionally producing an opposed first-cutter second cut surface terminating in the opposed ends of the first polymeric foamed material and opposed to the first-cutter second cut surface to form a first-cutter second slot in the first polymeric foamed materials such that after the disposing step (f) the first web and the first flange of the first brace member are further disposed respectively in the first-cutter first slot and in the first-cutter second slot. The cutting step (i) preferably additionally produces an opposed second-cutter first cut surface terminating in the opposed ends of the second polymeric foamed material and opposed to the second-cutter first cut surface to form a second-cutter first slot in the second polymeric foamed material. The cutting step (j) preferably additionally produces an opposed second-cutter second cut surface terminating in the opposed ends of the second polymeric foamed material and opposed to the second-cutter second cut surface to form a second-cutter seconds slot in the second polymeric foamed material such that after the disposing step (l) the second web and the second flange of the second brace member are further disposed respectively in the second-cutter first slot and in second-cutter second slot The first brace member and the second brace member may respectively comprise any suitable shape, such as a generally C-shape, and a portion of the first web of the first brace member may protrude from the first polymeric foamed material panel and/or a portion of the second web of the second brace member may protrude from the second polymeric foamed material panel. A structure produced in accordance with any of the methods of the embodiments of the present invention is an embodiment of the present invention.

Further alternative embodiments of the present invention also include a method for forming a structure comprising the steps of:

a) providing a first polymeric foamed material structure comprising a pair of opposed first ends, a first defined side surface, a first tongue, a first hotwire-cut seared surface having been cut by a hotwire cutter in a first direction relative to the first defined side surface and terminating in the pair of opposed first ends, a second hotwire-cut seared surface having been cut by a hotwire cutter in a second direction from the first hotwire-cut seared surface and terminating in the pair of opposed first ends, and a third hotwire-cut seared surface having been cut by a hotwire cutter in a third direction from the second hotwire-cut seared surface and terminating in the pair of opposed first ends;

b) providing a first brace member having a first web and at least one first flange secured to the web;

c) disposing respectively the first web and the first lange of the first brace member against the second hotwire-cut seared surface of step (a) and the third hotwire-cut seared surface of step (a) to produce a first polymeric foamed material panel having the first tongue;

d) providing a second polymeric foamed material structure comprising a pair of opposed second ends, a second defined side surface, a second channel, a first hotwire-cut seared surface having been cut by a hotwire cutter in a first direction relative to the second defined side surface and terminating in the pair of opposed second ends, a second hotwire-cut seared surface having been cut by a hotwire cutter in a second direction from the first hotwire-cut seared surface and terminating in the pair of opposed second ends, and a third hotwire-cut seared surface having been cut by a hotwire cutter in a third direction from the second hotwire-cut seared surface and terminating in the pair of opposed second ends;

e) providing a second brace member having a second web and at least one second flange secured to the web;

f) disposing respectively the second web and the second flange of the second brace member against the second hotwire-cut seared surface of step (d) and the third hotwire-cut seared surface of step (d) to produce a second polymeric foamed material panel having the second channel; and

g) disposing the first tongue of the first polymeric foamed material panel into the second channel of the second polymeric foamed material panel to form a structure. An embodiment of the present invention includes a structure formed in accordance with the immediate foregoing method.

Additional alternate embodiments of the present invention further include a method for producing a plurality of polymeric foamed material panels comprising the steps of:

a) cutting a polymeric foamed material with a plurality of cutters in a generally perpendicular direction from a defined surface (e.g., a side) of the polymeric foamed material;

b) cutting in at least a second direction the polymeric foamed material of step (a) with the plurality of cutters until each cutter forms in the polymeric foamed material a first respective slot terminating in opposed ends of the polymeric foamed material;

c) cutting with the plurality of cutters the polymeric foamed material of step (b) in the generally perpendicular direction of step (a) to produce a plurality of polymeric foamed material structures having first slots; and

d) disposing first brace members (e.g., Z-shape or (-shape brace members) in the first slots of the polymeric foamed material structures of step (c) to produce a plurality of polymeric foamed material panels with each polymeric foamed material panel having one of the first brace members.

The immediate foregoing method preferably additionally comprises cutting the polymeric foamed material with the plurality of cutters until each cutter forms a second respective slot in the polymeric foamed material and the produced plurality of polymeric foamed material structures include second slots, and disposing second brace members in the second slots of the produced polymeric foamed material structures such that each polymeric foamed material panel includes one of the second brace members. The first and second brace member include respectively a web which may protrude from the polymeric foamed material panel. This embodiment of the present invention includes polymeric foamed material panels formed in accordance with the immediate foregoing method.

Additional alternate embodiments of the present invention further provides a method for producing a plurality of polymeric foamed material panels comprising the steps of:

a) cutting a polymeric foamed material with a plurality of cutters in a generally perpendicular direction from a defined surface of the polymeric foamed material;

b) cutting in at least a second direction the polymeric foamed material of step (a) with the plurality of cutters until each cutter forms in the polymeric foamed material a first respective slot terminating in opposed ends of the polymeric foamed material;

c) cutting with the plurality of cutters the polymeric foamed material of step (b) in the generally perpendicular direction of step (a) to produce a plurality of polymeric foamed material structures having first slots; and

d) disposing first brace members in the first slots of the polymeric foamed material structures of step (c) to produce a plurality of polymeric foamed material panels with each polymeric foamed material panel having one of the first brace members.

In the immediate foregoing method, the first brace members preferably each comprise a generally C-shape, and the defined surface is a side of the polymeric foamed material. Each of the first brace members also preferably include a web portion which protrudes from the polymeric foamed material panel. The immediate foregoing method preferably additionally comprises cutting the polymeric foamed material with the plurality of cutters until each cutter forms a second respective slot in the polymeric foamed material and the produced plurality of polymeric foamed material structures include second slots, and disposing second brace members in the second slots of the produced polymeric foamed material structures such that each polymeric foamed material panel includes one of the second brace members. Embodiments of the invention also include a plurality of polymeric foamed material panels produced in accordance with the immediate foregoing method.

Further additional alternative embodiments of the present invention provide a method for producing a plurality of polymeric foamed material panels comprising the steps of:

a) providing a block of polymeric foamed material in a generally stationary position having a defined surface (e.g., a side of the block of the polymeric foamed materials) and a pair of opposed ends;

b) moving from the defined surface a plurality of cutters through the generally stationary block of polymeric foamed material of step (a) in generally perpendicular direction of travel;

c) interrupting the movement of the plurality of cutters from the generally perpendicular direction of travel through the generally stationary blocks of polymeric foamed material to move the cutters in at least one direction of travel which differs from the generally perpendicular direction of travel such that each cutter produces a respective brace-receiving slot in the polymeric foamed material terminating in the opposed ends;

d) continuing the moving step (b) of the plurality of cutters in the generally perpendicular direction of travel, while intermittently interrupting the movement of the plurality of cutters from generally perpendicular direction of travel to move the cutters in at least one direction of travel which differs from the generally perpendicular direction of travel such that each cutter produces at least one additional respective brace-receiving slot in the polymeric foamed material, until the plurality of cutters have moved completely through the generally stationary block of polymeric foamed material after which a plurality of polymeric foamed material structures are produced with each polymeric foamed material structure having a plurality of brace-receiving slots; and

e) disposing brace members into the brace-receiving slots of the polymeric foamed material structures of step (d) to produce a plurality of polymeric foamed material panels with each polymeric foamed material panel having two of the brace members. This embodiment of the present invention includes a plurality of polymeric foamed material panels produced in accordance with the immediate foregoing method.

Another additional embodiment of the present invention provides a method for producing a plurality of polymeric foamed material panels comprising the steps of:

a) cutting a polymeric foamed material in a first direction with a plurality of cutters generally moving in unison;

b) cutting subsequently the polymeric foamed material of step (a) in a second direction with the plurality of cutters generally moving in unison;

c) cutting, after the cutting step (b), the polymeric foamed material of step (b) in the first direction with the plurality of cutters generally moving in unison;

d) cutting, after the cutting step (c), the polymeric foamed material of step (c) in a third direction with the plurality of cutters generally moving in unison;

e) cutting, after the cutting step (d), the polymeric foamed material of step (d) in the first direction with the plurality of cutters generally moving in unison until the cutters have cut through the polymeric foamed material of step (d) to produce a plurality of polymeric foamed material structures having brace-receiving configurations; and

f) sliding brace members into the brace-receiving configurations of the polymeric foamed material structures of step (e) to produce a plurality of polymeric foamed material panels with each polymeric foamed material panel having one of the brace members. A plurality of polymeric foamed material panels produced in accordance with the immediate foregoing method is also an embodiment of the present invention.

An embodiment of the present invention also provides a method for producing a plurality of polymeric foamed material panels comprising the steps of:

(a) providing a block of polymeric foamed material having a defined surface (e.g., a side or a side surface or a defined side surface) and a pair of opposed ends;

b) moving from the defined surface a plurality of cutters through the block of polymeric foamed material in a generally perpendicular direction of travel, while interrupting at least one time the moving of the plurality of cutters in the generally perpendicular direction of travel to move the cutters through the block of polymeric foamed material in at least one direction of travel which differs from the generally perpendicular direction of travel, such that each cutter produces a respective brace-receiving slot in the polymeric foamed material terminating in the opposed ends, until the plurality of cutters have moved completely through the block of polymeric foamed material to produce a plurality of polymeric foamed material structures with each structure having at least one brace-receiving slot; and

c) disposing a brace member into each brace-receiving slot of the polymeric foamed material structures to produce a plurality of polymeric foamed material panels with each of the polymeric foamed material panels having at least one brace member. The foregoing embodiment of the present invention includes a plurality of polymeric foamed material panels produced in accordance with the immediate foregoing method.

Another embodiment of the present invention also includes a method for producing a polymeric foamed material panel comprising the steps of:

a) providing a block of polymeric foamed material having a defined surface and a pair of opposed ends;

b) cutting the block of polymeric foamed material in a first direction relative to the defined surface;

c) cutting the block of polymeric foamed material in a second direction produce a first slot including a first cut surface terminating in the opposed ends;

d) cutting the block of polymeric foamed material from the first slot to produce a second slot communicating with the first slot and including a second cut surface terminating in the opposed ends; and

e) disposing a brace member against the first cut surface and the second cut surface respectively in the first slot and in the second slot to produce a polymeric foamed material panel. The foregoing embodiment of the present invention includes a polymeric foamed material panel produced in accordance with the immediately foregoing method.

Further additional alternative embodiments of the present invention also provide a method for producing a plurality of polymeric foamed material structures having slot sections for receiving stud members comprising the steps of:

a) cutting a polymeric foamed material with a plurality of cutters (e.g., hotwire cutters and/or laser cutters which may be computer operated) in a generally perpendicular direction from a side of the polymeric foamed material;

b) cutting subsequently in at least a second direction the polymeric foamed material of step (a) with the plurality of cutters until each cutter forms a first respective slot section in the polymeric foamed material, the first respective slot section terminating in opposed ends of the polymeric foamed material; and

c) cutting in the generally perpendicular direction of step (a) the polymeric foamed material with the plurality of cutters to produce a plurality of polymeric foamed material strictures having a plurality of first slot sections, with each polymeric foamed material structure having one of the first slot sections.

In the immediate foregoing method the plurality of cutters preferably move generally simultaneously, and the polymeric foamed material of step (a), step (b) and step (c) is preferably generally stationary. The at least one second direction may comprise a second direction generally perpendicular to the generally perpendicular direction of step (a). The immediate foregoing method preferably additionally comprises cutting with the plurality of cutters, before the cutting step (c) and after the cutting step (b), the polymeric foamed material in the generally perpendicular direction of step (a) until each cutter formed a second respective slot section in the polymeric foamed material the second respective slot section communicating with the first perspective slot section and terminating in opposed ends of the polymeric foamed material; and the cutting step (c) subsequently produces a plurality of polymeric foamed material structures having a plurality of first slot sections and a plurality of second slot sections, with each polymeric foamed material structure having one of the first slot sections and one of the second slot sections. The immediate foregoing method preferably alternatively additionally comprises cutting with the plurality of cutters before the cutting step (c) and after the cutting step (b), the polymeric foamed material in the generally perpendicular direction of step (a) and subsequently in a fourth direction until each cutter forms a second respective slot section and a third respective slot section in the polymeric foamed material, the second respective slot section communicating with the first respective slot section and terminating in opposed ends of the polymeric foamed material and the third respective slot section communicating with the second respective slot section and terminating in opposed ends of the polymeric foamed material; and the cutting step (c) subsequently produces a plurality of polymeric foamed material structures having a plurality of first slot sections, a plurality of second slot sections, and a plurality of third slot sections, with each polymeric foamed material structure having one of the first slot sections, one of the second slot sections, and one of the third slot sections. The immediate foregoing method also preferably additionally comprises providing a plurality of stud members, and disposing the plurality of stud members in the first slot sections of the polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each polymeric foamed material panel having one of the stud members. The immediate foregoing method also preferably alternatively additionally comprises providing a plurality of stud members, and disposing the plurality of stud members in the first slot sections and in the second slot sections and in the third slot sections of the polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each of the polymeric foamed material panels having one of the stud members respectively occupying the first slot section, the second slot section and the third slot section associated with the each of the polymeric foamed material panels. A plurality of polymeric foamed material structure produced in accordance with the immediate foregoing method is also an embodiment of the present invention.

An alternative embodiment of the present invention provides a method for producing a plurality of polymeric foamed material structures having slots for receiving stud members comprising the steps of:

a) cutting a polymeric foamed material with a plurality of cutters (e.g., hot wire cutters, and/or laser cutters, which may be computer operated) in a generally perpendicular direction from a side surface of the polymeric foamed material;

b) cutting subsequently in at least a second direction the polymeric foamed material of step (a) with the plurality of cutters until each cutter forms a first respective slot; in the polymeric foamed material, the first respective slot terminating in opposed ends of the polymeric foamed material;

c) cutting in the generally perpendicular direction of step (a) the polymeric foamed material with the plurality of cutters to produce a plurality of polymeric foamed material structures having a plurality of first slots, with each polymeric foamed material structure having one of the first slots.

The immediate foregoing method may additional comprise cutting, prior to the cutting step (c) and after the cutting step (b), the polymeric foamed material with the plurality of cutters until each cutter forms a second respective slot in the polymeric foamed material, the second respective slot terminating in opposed ends of the polymeric foamed material; and the cutting step (c) subsequently producing a plurality of polymeric foamed material structures having a plurality of first slots and a plurality of second slots, with each polymeric foamed material structure having one of the first slots and one of the second slots. The polymeric foamed material may be generally stationary and the plurality of cutter may generally move simultaneously. The immediate foregoing method may additionally comprise providing a plurality of stud members wherein each of the stud members comprise a web and a flange integrally bound to the web; and disposing the plurality of stud members in the first slots and in the second slots of the polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each of the polymeric foamed material panels having the web and the flange of one of the stud members respectively occupying the first slot and the second slot associated with the each of the polymeric foamed material panels. Embodiments of the invention also include a plurality of polymeric foamed material structures produced in accordance with the immediate foregoing method.

A further alternative embodiment of the present invention provides a method for producing a plurality of polymeric foamed material structures having brace-receiving slots comprising the steps of:

a) providing a generally stationary block of polymeric foamed material having a side surface and a pair of opposed ends;

b) moving generally simultaneously from the side surface a plurality of cutters (e.g., hot wire cutters or laser cutters which may be computer operated) through the block of polymeric foamed material in a generally perpendicular direction of travel, while interrupting at least one time the moving of the plurality of cutters in the generally perpendicular direction of travel to move the cutters through the blocks of polymeric foamed material in at least one direction of travel comprising a direction which differs from the generally perpendicular direction of travel, such that each cutter producers a respective brace-receiving slot in the polymeric foamed material terminating in the opposed end, until the plurality of cutters have moved completely through the generally stationary block of polymeric foamed material to produce a plurality of polymeric foamed material structures having a plurality of brace-receiving slots, with each polymeric foamed material structure having at least one of the brace-receiving slots.

The immediate foregoing method additionally comprise providing a plurality of brace members; and disposing the plurality of brace members in the plurality of brace-receiving slots of the polymeric foamed material structures to produce plurality of polymeric foamed material panels, with each polymeric foamed material panel having at least one of the brace members. The at least one direction of travel may comprise a first direction of travel, a second direction of travel immediately following the first direction of travel and being generally parallel to the generally perpendicular direction of travel, and a third direction of travel immediately following the second direction of travel. The first direction of travel may be generally normal to the generally perpendicular direction of travel, and the second direction of travel may be generally normal to the first direction of travel. An additional embodiment of the present invention includes structures produced in accordance with the immediate foregoing method.

It is therefore an object of the present invention to provide a method for producing a polymeric foamed material panel.

It is another object of the present invention to provide a method for forming a polymeric foamed material structure.

It is yet further an object of the present invention to provide a polymeric foamed material panel.

These, together with the various ancillary objects and features which will become apparent to those skilled in the art as the following description proceeds, are attained by these novel methods and polymeric foamed material panels, a preferred embodiment being shown with reference to the accompanying drawings, by way of example only, wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1

is a perspective view of a polymeric foamed material panel produced in accordance with the method of the present invention;

FIG. 2

is a partial perspective view of a structure consisting of standard trusses and polymeric foamed material panels forming walls and roofs;

FIG. 2A

is another partial perspective view of a structure similar to the partial perspective view in

FIG. 2

wherein the structure includes standard trusses and polymeric foamed material panels forming walls and roofs;

FIG. 3

is a partial perspective view of a polymeric foamed material panel including a brace member having an opening with a conduit supported by the polymeric foamed material and passing through the opening of the brace member without contacting any of the circumference or perimeter of the opening of the brace member;

FIG. 4

is a partial perspective view of two panel members disposed contiguous to each other and encapsulated in sheetrock or the like;

FIG. 5

is a top plan view of the pair of contiguous panel members of

FIG. 4

encapsulated in sheetrock or the like;

FIG. 6

is a top plan view of a panel member having a plurality of steel studs or brace members disposed therein with the inside wall thereof covered with sheetrock and further having a tongue member at one end and a channel member at another end;

FIG. 7

is a perspective view of the hot wire cutter mounted on a table and operated by a computer;

FIG. 8

is a schematic diagram of the various process steps in producing the panel member of the present invention;

FIG. 9

is a perspective view of a hot wire cutter having cut through the polymeric foam material to a point where a subsequent general C-shaped slot is to be cut by the hot wire cutter, the C-shaped slot to be cut being represented by dotted lines;

FIG. 10

is a perspective view of the polymeric foamed material after a pair of C-shaped slots have been cut with the hot wire cutter and after the polymeric foam material has been rotated, with a hot wire cutter having cut a general cylindrical opening in the polymeric foam material transverse to the C-shaped slots, leaving a residual core material in the transverse opening; and further illustrating a metallic U-shaped stud in proximity to one of the C-shaped slots for being slid into the same;

FIG. 11

is an end elevational view of the residual core material being removed from the cylindrical opening in the polymeric foam material and with a conduit aligned with the cylindrical opening in order to be slid subsequently therein;

FIG. 12

is vertical sectional view of the polymeric foam material supporting a conduit while the conduit passes through an opening in the brace or stud member without touching any of the circumference or perimeter of the stud or brace member;

FIG. 13

is a partial perspective view of two polymeric foamed material panel members with ends of the two polymeric foamed material panel members being generally aligned such that the tongue on one end of one panel member may slid into a channel in one of the ends of the other panel member;

FIG. 14

is a partial vertical sectional view taken in direction of the arrows and along the plane of line

14

—

14

in

FIG. 8

;

FIG. 14A

is a vertical sectional view taken in direction of the arrows and along the plane of line

14

A—

14

A in

FIG. 14

;

FIG. 15

is a perspective view of a plurality of hot wire cutters cutting through a block of polymeric foamed material to produce a plurality of polymeric foamed structures having slots for receiving brace or stud members and having chases (or polymeric openings) wherethrough conduits pass;

FIG. 16

is a perspective view of a table assembly supporting a block of polymeric foamed material with a plurality of hot wire cutters passing and cutting through the polymeric foamed material block, and with the vertical and horizontal movement of the hot wire cutters being respectively controlled by a motor (M

V

) for controlling the vertical movement of the plurality of hot wire cutters and by a motor (M

H

) for controlling the horizontal movement of the plurality of hot wire cutters, wherein power to the motors M

V

and M

H

is allocated or metered from a CNC controller which receives signals from a computer;

FIG. 17

is an enlarged partial perspective view of a horizontal trolley supporting a vertical support of a harp and slidably engaged to a horizontal trolley track supported by the table assembly, and of a vertical trolley slidably mounted to the vertical support of the harp with a hot wire cutter coupled to the vertical trolley, such that the horizontal trolley can move the hot wire cutter in a horizontal direction and the vertical trolley can move the hot wire cutter in a vertical direction;

FIG. 18

is a schematic block diagram of the computer control assembly for controlling the plurality of hot wire cutters illustrating a computer, a CNC controller electrically engaged to the computer for receiving signals therefrom, a power box communicating with a power source and electrically engaged to the CNC controller to supply power to the CNC controller, and a pair of motors (M

V

and M

H

) electrically engaged to the CNC controller for receiving metered or allocated power from the CNC controller to control the vertical and horizontal movement of the plurality of hot wire cutters;

FIG. 19

is an end elevational view of a plurality of polymeric foamed structures produced after a plurality of computer-controlled hot wire cutters have passed through a block of polymeric foamed material;

FIG. 20

is an end elevational view of a polymeric foamed structure having a slot formed therein with a hot wire cutter with arrows representing directions and paths that the hot wire cutter travelled in forming the slot;

FIG. 20A

is an enlarged end elevational view of the polymeric foamed structure of

FIG. 20

with a stud or brace member lodged in the slot;

FIG. 20B

is an end elevational view of a pair of polymeric foamed material structures which were integrally bound to each other before being severed, with one polymeric foamed material structure having a polymeric material recess and with the other polymeric foamed material structure having a polymeric material crest which may serve as a benchmark or indicator for a brace member when the brace member is lodged in a slot located immediately below the polymeric material crest;

FIG. 21

is an exploded detail view of a section of the slot of

FIG. 20

with the hot wire cutter being shown in a dotted line representation and with the arrows showing the directions and paths of travel for the hot wire cutter;

FIG. 22

is an exploded detail view of another section of the slot of

FIG. 20

with the hot wire cutter being shown again in a dotted line representation and with the arrows showing again the directions and paths of travel for the hot wire cutter;

FIG. 23

is an enlarged view of the detail view of

FIG. 21

with “W” indicating the width of the slot and “D” indicating the diameter of the hot wire cutter;

FIG. 24

is an enlarged view of the detail view of

FIG. 22

;

FIG. 25

is an end elevational view of a polymeric foamed material structure produced from a block of polymeric foamed material and after a hot wire cutter has cut a plurality of slots (i.e., C-brace chases), a polymeric opening (i.e., a wiring chase), and a track chase in the polymeric foamed material structure;

FIG. 26

is another end elevational view of a polymeric foamed material structure produced from a block of polymeric foamed material and after a hot wire cutter has cut in the polymeric foamed material a plurality of slots or chases for receiving brace or stud members, a polymeric opening or wiring chase for receiving a conduct, and a track chase for receiving a track member;

FIG. 27

is an end elevational view of the polymeric foamed material structure of

FIG. 26

after brace or stud members (i.e., C-shaped braces or studs) have been slid into the plurality of slots or chases such that a portion of the brace members protrude from the polymeric foamed material structure;

FIG. 28

is an end elevational view of the polymeric foamed material structure of

FIG. 27

after a track member has been slid into the track chase and over the ends of the brace or stud members;

FIG. 28A

is a vertical sectional view taken in direction of the arrows and along the plane of line

28

A—

28

A in

FIG. 28

;

FIG. 28B

is a vertical sectional view taken in direction of the arrows along the plane of line

28

B—

28

B in

FIG. 28

;

FIG. 29

is an end elevational view of a polymeric foamed material structure produced from the block of polymeric foamed material and after a hot wire cutter has cut a plurality of slots or chases and a track chase in the polymeric foamed material structure;

FIG. 30

is an end elevational view of the polymeric foamed material structure of

FIG. 29

after a plurality of Z-shaped studs or braces have been inserted into the slots or chases such that a portion of the Z-shaped studs or braces protrudes from the polymeric foamed material structure;

FIG. 31

is an end elevational view of the polymeric foamed material structure in

FIG. 30

after a track member has been inserted into the track chase and over the ends of the Z-shaped studs or brace members;

FIG. 32

is an enlarged partial perspective view of an end of a polymeric foamed material structure after a hot wire cutter has cut a plurality of C-shaped slots in the polymeric foamed material structure and after a polymeric opening (i.e. a wiring chase) has also been cut in the polymeric foamed material structure by the hot wire cutter;

FIG. 33

is a partial perspective view of an end of a polymeric foamed material panel having a plurality of C-shaped studs or brace members inserted within slots in a polymeric foamed material structure with a portion of the studs or brace members protruding therefrom;

FIG. 34

is a partial perspective view of an end of a polymeric foamed material panel having a plurality of studs or brace members lodged in slots produced by a hot wire cutter with a portion of each of the studs or brace members protruding from the polymeric foamed material panel;

FIG. 35

is a vertical sectional view taken in direction of the arrows and along the plane of line

35

—

35

in

FIG. 34

, illustrating a track chase which was cut in the polymeric foamed material by a hot wire cutter;

FIG. 36

is a perspective view of a polymeric foamed material panel having a plurality of braces embedded therein with a vertical conduit having been slid into a vertical wiring chase, and with a horizontal conduit having been slid into a horizontal wiring chase, and including an internal reinforcing member lodged within a horizontal polymeric opening with a male end of the internal reinforcing member protruding from a side of the polymeric foamed material panel; and

FIG. 37

is a partial side elevational view of a pair of engaged polymeric foamed material panels having respective internal reinforcing members with the male end of one internal reinforcing member lodged in the female end of the other internal reinforcing member.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring in detail now to the drawings wherein similar parts of the invention are identified by like reference numerals, there is seen a panel member, generally illustrated as

10

, produced in accordance with the method of the present invention. The panel member

10

comprises a polymeric foamed material, generally illustrated as

12

, and a plurality of stud or brace members

14

disposed in the polymeric foamed material

12

. The polymeric foamed material

12

has a pair of opposed ends

12

f

and

12

g

(see

FIGS. 6

,

9

and

10

). Each of the brace members

14

pass into a slot, generally illustrated as

30

(see FIGS.

4

and

8

), which was preferably preformed or precut. As best shown in

FIGS. 6 and 29

, slot

30

may be non-linear. Each of the brace members

14

may be any suitable brace member such as studs, load-bearing members, etc. constructed of any suitable material (e.g. metal, wood, etc.) Most preferably, the brace members

14

are metal (e.g. a light gauge metal) studs for load-bearing and adding strength to the polymeric foamed material

12

. As best shown in

FIGS. 1 and 6

, each brace member

14

includes brace sides

14

a

,

14

b

,

14

c

, and

14

d

and

14

e

which are all essentially surrounded by the polymeric foamed material

12

. Stated alternatively and as best shown in

FIGS. 33 and 34

, each stud or brace member includes a web

14

w

, a pair of flanges

14

f

—

14

f

integrally secured to the web

14

w

, and a pair of flange returns

14

r

—

14

r

, respectively integrally bound to the respective flanges

14

f

—

14

f.

In the embodiment of the invention shown in

FIGS. 30 and 31

, each stud or brace member

14

is generally geometrically Z-shaped with the web

14

w

being oblique with respect to flanges

14

f

—

14

f

as opposed to being normal thereto as shown in

FIGS. 31 and 35

. In the embodiment of the invention shown in

FIGS. 27

,

28

,

30

,

31

,

33

and

34

a portion of each stud or brace member protrudes from the polymeric foamed material

12

. More specifically, one of the flanges

14

f

—

14

f

and its associated flange return

14

r

, along with a portion of the web

14

w

, are embedded in the polymeric foamed material

12

, while the remaining flange

14

f

and its associated flange return

14

r

, along with a remaining portion of the

14

w

, are disposed outside of the polymeric foamed material

12

.

Referring now to

FIGS. 20 and 20A

, there is seen a slot

30

communicating with a polymeric material recess

12

r

. Slot

30

and polymeric material recess

12

r

were cut in the polymeric foamed material in accordance with a cutting procedure set forth hereinafter. As best shown in

FIGS. 20

,

21

and

22

, the slot

30

more specifically includes vertical slot section having opposed cut surfaces

30

r

1c

—

30

r

1c

terminating in the opposed ends

12

f

and

12

g

and a generally inverted L-shaped slot section

30

which includes individual slot sections

30

w

,

30

f

and respectively having opposed cut surfaces

30

w

c

—

30

w

c

,

30

f

c

—

30

f

c

and

30

r

2c

—

30

r

2c

. As best shown in

FIG. 20

, slot sections

30

r

1

, and

30

w

directly communicate with the polymeric material recess

12

r

having cut surface

12

r

2

. A brace member

14

lodges in slot section

30

r

1

, in polymeric material recess

12

r

, and in slot section

30

s

. More specifically and as best shown in

FIG. 20A

, one flange return

14

r

and one flange

14

f

of a brace member

14

respectively lodges in slot section

30

r

1

and polymeric material recess

12

r

and respectively against cut surfaces

30

r

1c

—

30

r

1c

, and cut surface

12

r

c

, while the remaining web

14

w

, flange

14

f

and flange return

14

r

of the brace

14

respectively lodges in slot section

30

w

and against cut surfaces

30

w

c

—

30

w

c

, slot section

30

f

and against cut surfaces

30

f

c

—

30

f

c

, and slot section

30

r

2

and against cut surfaces

30

r

2c

—

30

r

2c

, of the slot section

30

s

. As further best shown in

FIGS. 20

,

20

A and

20

B, there is seen acut surface, generally illustrated as

12

cs

and including cut surface

12

cs

1

(e.g., a defined planar surface

12

cs

1

) and cut surface

12

cs

2

(e.g., a defined planar surface

12

cs

2

). As best shown in

FIG. 20A

, web

14

f

of brace member

14

is generally aligned with cut surface

12

cs

, more specifically with cut surfaces

12

cs

1

and

12

cs

2

. As will be further indicated hereinafter, if a hot wire (identified as “

58

” below) is used as a cutter for cutting or forming slot(s)

30

including the associated cut surfaces (e.g.,

30

w

c

—

30

w

c

,

30

f

c

—

30

f

c

,

30

r

2c

—

30

r

2c

, etc.), the cut surface(s) are seared surfaces.

After a polymeric material recess

12

r

has been cut in a polymeric foamed material

12

, the polymeric foamed material

12

adjacent or contiguous to the polymeric foamed material

12

having the polymeric material recess

12

r

has a polymeric material crest or ridge

12

c

as best shown in FIG.

20

B. This polymeric material crest

12

c

previously integrally resided within the polymeric material recess

12

r

, and may be either removed, such as by sanding, or be used as a benchmark or indicator for a location of a brace member

14

. Referring more particularly to

FIG. 20B

wherein there is seen two severed polymeric foamed materials

12

a

and

12

b

, with polymeric foamed material

12

a

having polymeric material recess

12

r

and with polymeric foamed material

12

b

having the polymeric material crest

12

c

. Each of the polymeric foamed materials

12

a

and

12

b

respectively include the following as best shown in FIG.

20

B: cut surface

12

cs

including cut surfaces

12

cs

1

and

12

cs

2

; slot section

30

r

1

having opposed cut surfaces

30

r

1c

—

30

r

1c

; polymeric material recess

12

r

including cut surface

12

r

c

; slot section

30

w

comprising opposed cut surfaces

30

w

c

—

30

w

c

; slot section

30

f

including opposed cut surfaces

30

f

c

—

30

f

c

; and slot section

30

r

2

having opposed cut surfaces

30

r

2c

—

30

r

2c

. When a brace member

14

is slid into the slot

30

of the polymeric foamed material

12

b

, the brace member

14

in the polymeric foamed material

12

b

would be immediately below (e.g. one (1) to three (3) inches below) the polymeric material crest

12

c

. Thus, a person looking at the planar side of polymeric foamed material

12

b

having the polymeric material crest

12

c

, and not being able to see the planar side of the polymeric foamed material

12

b

where the brace member

14

is exposed, would still know that immediately below the polymeric material crest

12

c

lies a brace member

14

. Thus, the polymeric material crest

12

c

may serve as a benchmark or indicator for the location of a brace member

14

.

In the embodiment of the invention shown in FIGS.

25

-

31

,

34

and

36

, the polymeric foamed material

12

includes a track chase

100

(i.e., a cut slot ranging from about one-quarter (¼) inch to about 1{fraction (1/2 )} inches in depth), as best shown in

FIG. 35. A

track member

102

is provided and includes a track base

104

with a pair of track flanges

105

-

106

integrally bound thereto. As best shown in

FIGS. 28A and 28B

, one of the track flanges

106

may lodge in the track chase

100

with a portion of the track base

104

extending away from the polymeric foamed material

12

(see FIG.

28

A), such that one of the track flanges

106

associated with the track base

104

is situated outside of the polymeric foamed material

12

. The track flange

106

disposed outside of the polymeric foamed material

12

may be secured to one of the flanges

14

f

of the stud or brace member

14

by a screw or bolt

107

as best shown in FIG.

28

B.

The panel member

10

may additionally include a conduit

16

also disposed in the polymeric foamed material

12

, preferably transversely disposed therein and generally normal with respect to the brace members

14

. The conduit

16

passes into a transverse polymeric opening

17

(see

FIGS. 10 and 11

) in the polymeric foamed material

12

. In the embodiment of the invention shown in FIGS.

15

-

35

, the polymeric foamed material

12

in the panel member

10

is provided with a longitudinal (and/or vertical) polymeric opening

15

which is preferably for receiving a conduit

19

(see FIG.

36

). The conduits

16

and

19

may be employed for any suitable use; for example, a utility receptor (e.g. electrical wires), water, gas, etc. The polymeric openings

15

and

17

as well as slot

30

are preferably formed with at least one seared or cartherized wall

32

. Cartherizing and/or searing the wall(s) of the polymeric openings

15

and

17

and/or slot

30

hardens and smoothes the wall(s) to facilitate the sliding of the conduits

16

and

19

and to brace member(s)

14

thereinto. As will be further explained below, the seared or cartherized wall

32

is preferably formed by hot wire cutting.

The panel member

10

may also additionally include an internal reinforcing member, generally illustrated as

23

in FIG.

36

. The reinforcing member

23

includes a male end

23

m

and a female end

23

f

. When two panels

10

—

10

are placed next to each other in a side-to-side relationship for assembling a structure, the male end

23

m

of one reinforcing member

23

in one panel

10

slidably lodges into the female end

23

f

of the other panel

10

, as best shown in FIG.

37

. The reinforcing member

23

lodges in a transverse polymeric opening

25

, which is formed similarly as transverse polymeric opening

17

is formed. The reinforcing member

23

preferably extends from a tongue (identified as “

24

” below) on one end of the panel member

10

to a channel (identified as “

26

” below) on the other end of the panel member

10

. Thus, the male end

23

m

of the reinforcing member

23

would protrude from a tongue while the female end

23

f

of the reinforcing member

23

would communicate with a channel. Transverse polymeric opening

25

is formed with at least one seared or cartherized wall

32

to facilitate the sliding of the reinforcing member

23

thereinto.

Each of the brace members

14

has an opening

18

that has a circumference (or perimeter) which is larger than the circumference (or perimeter) of the conduit

16

and larger than the circumference (or perimeter) of the polymeric opening

17

such that after any and all openings

18

have been aligned with any and all polymeric openings

17

, the conduit

16

may pass through a respective polymeric opening

17

and through a respective polymeric opening

18

in the brace members

14

, preferably without contacting any of the circumferential perimeter of the opening

18

and be supported in a suspended relationship with respect thereto by the polymeric foamed material

12

. When ever “perimeter” is stated in the specification and in the claims, it is to be understood to mean any boundary of any opening (e.g. a square opening, a circular opening, etc.) Thus, the term “perimeter” is to include opening, circumference.

For the embodiment of the invention shown in

FIGS. 36 and 37

, each of the brace members

14

would have an additional opening

18

that has a circumference (or perimeter) which is larger than the circumference (or perimeter) of the internal

5

reinforcing member

23

and larger than the circumference (or perimeter) of the polymeric opening

25

such that after any and all additional openings

18

have been aligned with any polymeric opening

25

, the internal reinforcing member

23

may lodge in the polymeric opening

25

and pass through the additional opening

18

in the brace members

14

, preferably without contacting any of the circumferential perimeter of the additional opening

18

such as to be supported in a suspended relationship with respect thereto by the polymeric foamed material

12

.

Each of the panel members

10

also preferably includes ends

20

and

22

(each a defined edge). End

20

is formed with a tongue

24

and the end

22

is formed with a channel

26

. Formation of the tongue

24

and/or the channel

26

is preferably accomplished by cutting (preferably hot wire cutting) a portion

36

(see

FIG. 8

) of polymeric foamed material

12

off of the end

20

and/or end

22

respectively. As best shown in

FIG. 13

, a pair of panel members

10

—

10

may be interengaged by sliding the tongue

24

of end

20

into the channel

26

of end

22

to form a structure. As further best shown in

FIG. 13

, each of the panel members

10

includes the brace member

14

having the opening

18

with the conduit

16

passing through and between the two interengaged panel members

10

—

10

such that the polymeric foamed material

12

of each of the panel members

10

supports the conduit

16

in a space relationship with respect to the perimeter (i.e. circumference) of each of the openings

18

. In other words, the conduit

16

is preferably not to contact any part of the brace member

14

.

The polymeric foamed material

12

of the present invention may be any suitable material that is capable of producing the panel

10

of the present invention, preferably a suitable material that is capable of being cut and/or burned and/or melted (i.e. hot wire cut or melted) to produce the panel

10

of the present invention. The polymeric foamed material

12

may be either high density and/or low density polymeric material. The polymeric foamed material

12

provides significant insulating qualities and thereby reduces heat and cooling costs as compared with conventional fiberglass batt insulation of equal thickness. Furthermore, the polymeric foamed material

12

in combination with the plurality of brace members

14

may be customized to provide complete design flexibility and superior structural advantages in shear strength and lateral load capability. The polymeric foamed material

12

exhibits a high strength to weight ratio and also exhibits superior insulating properties. The polymeric foamed material panel

10

provides both a structure and a substrate for the interior and exterior finishes.

Suitable polymeric foamed materials

12

have been discovered to be heat expandable plastic materials, such as pelletized polystyrene and the like. Other suitable heat expandable plastic materials that are within the spirit and scope of the present invention for the polymeric foamed material

12

is polyethylene, polyurethane, polypropylene, polyvinylchloride, etc., all being at a density to provide good thermal insulation and strength. The density is preferably of the order of about {fraction (1/2 )} pound per cubic foot to about 8 pounds per cubic foot. A density of from about 1 pound per cubic foot to about 3 pounds per cubic foot has been found to provide very good thermal properties as well as excellent physical properties including strength.

The heat expandable plastic material also provides for excellent burn-back or melt-back qualities when cut by a laser cutter (not shown) or by a hot wire cutter (identified as “

50

” below). When the below identified hot wire cutter cuts the heat expandable plastic material, the material typically burns and melts, more specifically melts back, to form the polymeric openings

15

,

17

and

25

and slot

30

within the polymeric foamed material

12

. Prior to commencing the formation of polymeric openings

15

,

17

and

25

and/or slot

30

(i.e. a brace-receiving configuration or brace-receiving configured slot

30

) within the polymeric foamed material

12

, the below identified hot wire cutter cuts and/or burns and/or melts back from a surface

74

(i.e. a defined surface

74

) a slot

70

(preferably a generally straight thread-like slot

70

with a seared wall

32

) down to a point

72

(i.e. a preconfiguration cut point

72

) whereafter the below identified hot wire cutter cuts and/or burns and/or melts back the heat expandable plastic material to produce the polymeric openings

15

,

17

and

25

and/or slots

30

. The polymeric opening

17

is more technically produced after a residual core

12

A (see

FIG. 11

) is removed in any suitable manner or by any suitable means. The polymeric openings

15

and

25

are similarly produced, with the residual cores for polymeric openings

15

and

25

not being shown.

Certain epoxy resinous materials have also been discovered to be suitable polymeric foamed material

12

. Other suitable polymeric foamed material(s)

12

for the present invention include a rigid polystyrene, polyurethane, or polyisocyanurate foam or styrofoam. The polymeric foamed material

12

of the present invention provides for prefabricated panels

10

that may be easily installed at a building site for constructing a house, an industrial building, or any other structure, generally illustrated as

40

in

FIGS. 2 and 2A

.

The most preferred polymeric foamed material

12

from which the panel

10

is to be constructed is expanded polystyrene beads. It is lightweight, quite strong and has excellent insulating qualities. On an outside wall

42

(see

FIG. 6

) of the polymeric foamed material panel

10

, a sheet of outer skin facing material

46

(such as one or more asbestos cement sheet, plywood, reconstituted timer sheeting, flat steel sheet, profiled steel sheet, rigid plastic sheet or flexible metal or plastic film or various combinations of outer skins) may be mounted or secured thereto. Examples of other exterior finishes which may be applied include one or more of: EIFS, stucco, metal cladding roofing material, ceramic tiling, wood, vinyl or other treatment customarily used in building construction. On an inside wall

48

(see

FIG. 6

again) of the polymeric foamed material panel

10

, a sheet of inner skin facing material

49

(e.g. sheet rock or the like) may be mounted or secured thereto. The sheet of inner skin facing material

49

may be any one or more suitable material(s) customarily employed in finishing the inside walls, roofs, etc., in building construction.

A hot wire cutter assembly, generally illustrated as

50

(see FIG.

7

), is preferably provided for cutting and searing purposes. The hot wire cutter assembly

50

is electrically engaged to a computer

52

via one or more conductors

54

. The hot wire cutter assembly

50

is typically mounted on a table assembly

56

whereupon polymeric foamed material

12

is placed to be hot wire cut. The hot wire cutter assembly

50

includes at least one wire

58

for receiving current to be heated and to be moved for cutting and searing proposes in accordance with commands from the computer

52

, or from manual commands.

The hot wire cutter assembly

50

may be any suitable hot wire cutter assembly that is capable of cutting the desired slots (e.g. generally C-shaped or Z-shaped slots

30

and generally vertical or straight thread-like slots

70

, etc.) and openings (e.g. polymeric openings

17

, etc.) in the polymeric foamed material

12

. A suitable hot wire cutter assembly

50

is commercially available from Starr Mfg., Inc., a division of Starr Foam, Inc. of Fort Worth, Tex. The computer

52

to operate the hot wire cutter assembly

50

may also be obtained from Starr Mfg., Inc. The wire(s)

58

of the hot wire cutter assembly

50

preferably has a diameter ranging from about 0.03 inch to about 0.07 inch, more preferably from about 0.04 inch to about 0.06 inch. The wire(s)

58

typically receives less than approximately ten (10) amps at a difference of potential of about 110 volts. At a difference in potential of about 220 volts the wire(s)

58

would receive less than about five (5) amps. It is to be understood that the wire

58

may have any suitable diameter, and operate at any suitable voltage or amperage, for practicing the present invention.

Referring in detail now to FIGS.

15

-

18

, there is seen another embodiment for the hot wire cutter assembly

50

as comprising a plurality of wires

58

for cutting through a block, generally illustrated as

8

, of polymeric foamed material

12

. The hot wire cutter assembly

50

is available commercially from HP Machine, 1600 West Acoma Blvd., Lake Havasu, Ariz. 86403, under product model number: Model S-TEL-9000 CNC. The hot wire cutter assembly

50

includes a table assembly, generally illustrated as

120

, upon which the block

8

of polymeric foamed material

12

lies while movement of the plurality of wires

58

during the cutting procedure are controlled by a computer control assembly

200

(see FIG.

18

). The wires

58

of the hot wire cutter assembly

50

for the embodiment of the invention shown in FIGS.

15

-

18

preferably have a diameter ranging from about 0.03 inch to about 0.07 inch, more preferably from about 0.04 inch to about 0.06 inch. The wires

58

typically receive less than approximately ten (10) amps at a difference of potential of about 110 volts. At a difference in potential of about 220 volts the wires

58

would receive less than about five (5) amps. It is to be understood that the wires

58

may have any suitable diameter, and operate at any suitable voltage or amperage, for practicing the present invention.

The table assembly

120

includes a table

124

having a pair of generally identical horizontal track assemblies

128

—

128

connected thereto. A horizontal trolley assembly

130

is slidably mounted to each of the horizontal track assemblies

128

. Only one of the horizontal trolley assemblies

130

is shown in

FIG. 16

, with the other horizontal trolley assembly

130

(not shown) being broadly referenced by a broken-line arrow from

130

. The table assembly

120

also includes a support harp

134

having a horizontal support section

136

and a pair of opposed vertical support sections

138

—

138

integrally bound to the horizontal support section

136

. As best shown in

FIG. 17

, the respective vertical support sections

138

are supported respectively by one of the horizontal trolley assemblies

130

such that when both of the horizontal trolley assemblies

130

—

130

move in a certain horizontal direction, the support harp

134

also moves in the same horizontal direction. Each of the vertical support sections

138

slidably supports a vertical trolley assembly

150

to which the plurality of wires

58

couple such that when the vertical trolley assemblies

150

—

150

are moved by the computer control assembly

200

in a certain vertical direction, the plurality of wires

58

move accordingly in the same vertical direction. Thus, computer control assembly

200

for the present invention, may move the wires

58

either horizontally or vertically, or both horizontally and vertically simultaneously to form any desired shape for the slots

30

or form the cylindrical shaped polymeric openings

15

,

17

and

25

.

The horizontal track assemblies

128

each include a main table frame

154

having a horizontal trolley track

156

as best shown in FIG.

17

. As further best shown in

FIG. 17

, the horizontal trolley assembly

130

comprises a horizontal trolley

160

slidably mounted along the horizontal trolley track

158

, a horizontal locking assembly

164

for locking the horizontal trolley

160

, and a drive brace

168

bound to the horizontal trolley

160

and coupled to a horizontal drive cable

170

such that when the horizontal drive cable

170

is moved in a certain horizontal direction by hand or by a motor (identified as “M

H

” below), the drive brace

168

also moves, causing the horizontal trolley

160

to also move, in the same certain horizontal direction. The horizontal drive cable

170

is also similarly engaged and coupled to the other horizontal trolley assembly

130

(not shown) through a series of pulleys (not shown) underneath the table

124

such that both horizontal trolley assemblies

130

—

130

are capable of being moved in unison and in the same horizontal direction by a motor (identified as “M

H

” below). As was previously indicated, when the horizontal trolley assemblies

130

—

130

are moved in a certain horizontal direction, the support harp

134

(and the wires

58

) also moves in the same certain horizontal direction.

Each of the vertical trolley assemblies

150

include a sleeve

174

movably engaged to one of the vertical support sections

138

of the support harp

138

, as best shown in

FIGS. 16 and 17

. Each of the vertical trolley assemblies

150

have a manual actuation knob

176

, a vertical locking mechanism

178

, and a vertical drive cable

180

coupled to the sleeve

174

. The plurality of wires

58

are coupled to the sleeve

174

such as to move vertically therewith. When the vertical drive cable

180

is moved in a certain vertical direction by a motor (identified as “M

V

” below), the sleeve

174

(along with the plurality of wires

58

coupled thereto) also moves in the same certain vertical direction. The vertical drive cable

180

is also similarly engaged and coupled to the sleeve

174

of the other vertical trolley assembly

150

through a series of pulleys (not shown) such that both vertical trolley assemblies

150

—

150

are capable of being moved in unison and in the same vertical direction by hand or by a motor (identified as “M

V

” below). As previously mentioned, when the vertical trolley assemblies

150

—

150

are moved in a certain vertical direction along the vertical support section

138

of the support harp

134

, the wires

58

also move in the same certain vertical direction. As best shown in

FIG. 17

, an electrical conductor

186

is coupled to the wires

58

and communicates with a power source for conducting electrical power from the power source to the wires

58

for heating the same.

Referring now to

FIG. 18

for the computer assembly

200

of the present invention, there is seen the computer

52

electrically engaged to a CNC controller

210

via at least one conductor

214

. CNC controller

210

is electrically engaged to motor M

V

to motor M

H

and to power box

220

via conductor

222

, conductor

224

, and conductor

228

respectively. Power box

220

communicates with a power source through at least one conductor

230

for receiving electrical power and administering the same to the CNC controller

210

through conductor

228

. Through a program in the computer

52

, appropriate signals are sent to the CNC controller

210

which in turn releases and/or allocates electrical power to the two motors M

V

and M

H

based on the signals received from the computer

52

. As was previously indicated, the motors M

V

and M

H

respectively control the vertical and horizontal movement of the wires

58

by moving the vertical trolley assemblies

150

and the horizontal trolley assemblies

130

respectively. The computer control assembly

200

is available commercially from HP Machine, 1600 West Acoma Blvd., Lake Havasu, Ariz. 86403.

Continuing to refer to the drawings for operation of the invention and the method for producing the panel

10

, the polymeric foamed material

12

is placed upon the table assembly

56

and under (i.e. laterally adjacent to) the wire

58

of the hot wire cutter assembly

50

. While operation of the invention is being initially illustrated with respect to a wire cutter assembly

50

having a single wire

58

, a wire cutter assembly

50

having a plurality of wires

58

would operate similarly. Commands are entered into the computer

52

and the wire

58

is heated to a desired temperature (e.g. from about 230° F. to about 580° F., preferably from about 250° F. to about 350° F.) and the now hot wire

58

is lowered against the surface

74

and commences to cut and/or burn and/or melt back the polymeric foamed material

12

to produce the generally straight thread-like vertical slot

70

. The slot

70

is continually formed or produced until the hot wire

58

reaches point

72

(see

FIG. 9

) whereupon the computer

52

sends another signal to the hot wire cutter assembly

50

, causing the hot wire

58

to be moved in an essentially generally C-shaped path (as represented by dotted lines in

FIG. 9

) to produce an essentially generally C-shaped slot

30

. One or more of these slot(s)

30

may be formed in the polymeric foamed material

12

such as to terminate in the pair of opposed ends

12

f

and

12

g

of polymeric foamed material

12

(see FIGS.

10

and

19

). As best shown in

FIG. 10

, two slot(s)

30

were produced in the polymeric foamed material

12

.

After the hot wire

58

has cut the slot(s)

30

and

70

, the cutting path(s) is reversed by commands from the computer

52

such that the hot wire

58

reversely retraces its initial cutting path(s), which reverse retracing typically causes more burning and/or melt back of polymeric foamed material

12

contiguous to the slot(s)

30

and

70

. In reverse retracing of its initial cutting path, the hot wire

58

is “cleaning out” the slot(s)

30

and slot(s)

70

that terminate in slot(s)

30

for further defining the slot(s)

30

and

70

, especially slot

30

which is of an opening between opposed perimetrical boundaries approximating the thickness of the brace member

14

for snugly receiving the brace member

14

to essentially fully encapsulate the same. Preferably, slot(s)

30

have openings that are greater than the opening of slot(s)

70

that terminate in slot(s)

30

. In reverse retracing of its initial cutting path(s), the hot wire

58

further sears and/or cartherizes the seared wall(s)

32

of the slot(s)

70

and

30

to further harden and smooth the same. After the hot wire

58

has reversely retraced its initial cutting path(s), the hot wire

58

exits out of slot

70

that terminates in slot

30

and is subsequently elevated above the surface

74

.

After forming the desired number of slot(s)

30

, the polymeric foamed material

12

is subsequently preferably rotated on top of the table assembly

56

in order to posture the polymeric foamed material

12

for formation of the polymeric opening(s)

17

. This obviously is an optional step since there are times that the polymeric foamed material panel

10

is to be produced without any polymeric opening(s)

17

. The amount of rotation of the polymeric foamed material

12

for forming polymeric opening(s)

17

would be any suitable amount to accomplish the desired cutting results. Preferably, for a square or rectangular shaped polymeric foamed material

12

as shown in

FIGS. 9 and 10

, the rotation would be approximately 90° such that the polymeric opening

17

to be formed would be generally normal to the slot(s)

30

.

In forming the polymeric opening

17

, the hot wire

58

is lowered by the hot wire cutter assembly

50

against the surface

74

and another slot

70

is commenced to be cut by the hot wire

58

. The slot

70

is continually cut until a point

72

(i.e. a preconfiguration cut point

72

) is again reached whereupon the computer signals the hot wire cutter assembly

50

to move the hot wire

58

in a circular fashion or manner to cut and/or burn and/or melt back polymeric foamed material

12

such that when the core material

12

A is removed, the polymeric opening

17

is produced with slot

70

terminating in polymeric opening

17

. As previously indicated, removal of the core material

12

A may be by any suitable means including manual removal of it.

As was seen in the production of slot(s)

30

and

70

, after the hot wire

58

has cut polymeric opening

17

(i.e. cylindrical polymeric opening

17

) and slot(s)

70

that terminate in polymeric opening(s)

17

, the cutting path(s) (e.g. a cylindrical cutting path) is reversed by commands from the computer

52

such that the hot wire

58

reversely retraces its initial cutting path(s) in the formation of polymeric opening

17

. Such reverse retracing causes more burning and/or melt back of polymeric foamed material

12

contiguously or juxtaposedly exposed on the initially seared wall(s)

32

of the polymeric opening

17

and the slot(s)

70

. In reverse retracing of its initial cutting path(s), the hot wire

58

is also further searing and/or cartherizing the wall (i.e. the cylindrical wall) around the core material

12

A to further smooth and harden the same to facilitate the removal of the core material

12

A. As was previously indicated for the formation of slot(s)

30

, by reversely retracing its initial cutting path(s), the hot wire

58

is “cleaning out” the polymeric opening(s)

17

and slot(s)

70

terminating in polymeric opening(s)

17

for further defining polymeric opening(s)

17

and slot(s)

70

, especially the polymeric opening(s)

17

which for cylindrical polymeric opening(s)

17

have a diameter that approximates the diameter of conduit

16

for snugly receiving conduit

16

to essentially fully encapsulate the same. Also by reverse retracing of its initial cutting path(s), the hot wire

58

further sears and/or cartherizes the seared wall(s)

32

of polymeric opening(s)

17

and the slot(s)

70

terminating in the polymeric opening (s)

17

to further harden and smooth the same. After the hot wire

58

has reversely retraced its initial cutting path(s) in the formation of polymeric opening(s)

17

, the hot wire

58

exits out of the slot

70

terminating in the polymeric opening

17

and is then elevated above the surface

74

.

After the core material

12

A has been removed from polymeric opening

17

, the brace member

14

(see

FIG. 10

) is aligned with the general C-shaped slot

30

(see

FIG. 10

) and is subsequently pushed into the cut slot

30

such that the brace member

14

would preferably extend from one extremity of the polymeric foamed material

12

to another extremity of the polymeric foamed material

12

. In order words, it is preferred that the brace member

14

extends entirely through the polymeric foamed material

12

such that ends of the brace member

14

are exposed at opposed ends

12

f

and

12

g

of the polymeric foamed material

12

. This enables a more optimal load-bearing function for the brace members

14

. Each brace member

14

is preferably inserted into each slot

30

.

The brace members

14

may be typically provided with the opening (s)

18

which is capable of being aligned with the polymeric opening(s)

17

when and after the brace member(s)

14

are slid into the slot(s)

30

(i.e. preferably generally C-shaped slot(s)

30

) in the polymeric foamed material

12

. After such alignment, one or more panels

10

may be sent to a construction site such that two or more of the panel(s)

10

may be combined in any desired manner (e.g. contiguous as shown in

FIGS. 4 and 5

or aligned as shown in

FIG. 13

) to produce a structure

40

. When postured in an alignment in accordance with

FIG. 13

, the conduit

16

may be slid through the polymeric opening(s)

17

and through the opening(s)

18

(see

FIG. 1

) in the brace member(s)

14

, preferably such that the conduit

16

is supported by the polymeric foamed material

12

in the two or more panels

10

and preferably such that the conduit

16

does not contact any perimeter of the opening(s)

18

in the brace member(s)

14

.

The tongue

24

and the channel

26

may be cut in the opposed ends

20

and

22

of the polymeric foamed material

12

at any desired time. More specifically, the tongue

24

and the channel

26

may be cut after the generally C-shaped slot(s)

30

and polymeric opening(s)

17

have been cut in the polymeric foamed material

12

, or the tongue

24

and the channel

26

may be cut before the generally C-shaped slot(s)

30

and polymeric opening(s) have been cut in the polymeric foamed material

12

. After the tongue

24

and the channel

26

have been formed, any wall(s) that the hot wire

58

has contacted is or becomes seared wall(s)

32

. Thus, the wall(s) of the channel

26

and the tongue

24

are seared wall(s)

32

.

Continuing to refer to the drawings for operation of another preferred embodiment of the present invention including the method(s) for producing the panel

10

, the block

8

of the polymeric foamed material

12

is placed upon the table

124

of the table assembly

120

and next (i.e. laterally adjacent) to the wires

58

of the hot wire cutter assembly

50

. The wires

58

are positioned along a side

8

s

(i.e. a surface or a side surface or a defined surface or a defined side surface, see

FIGS. 15 and 16

) of the block

8

of the polymeric foamed material

8

. The wires

58

are heated to a desired temperature (e.g. from about 230° F. to about 580° F.). The computer control assembly

200

may be programmed to cause the motors M

H

and M

V

to move the wires

58

in any desired direction for any desired distance such that a plurality of panels

10

may be produced from the block

8

of polymeric foamed material

12

. Preferably, the wires

58

are caused to be initially moved by the computer control assembly

200

to cut a plurality of tongues

24

in the side

8

s

of the block

8

of polymeric foamed material

8

. After the tongues

24

have been formed (see FIGS.

15

and

16

), the wires

58

are caused to be moved by the computer control assembly

200

to subsequently cut a plurality of slots

30

in the block

8

of polymeric foamed material

12

and to sever the block

8

into a plurality of polymeric foamed materials

12

(i.e. a plurality of polymeric foamed material structures

12

s

shown in FIG.

19

), with each polymeric foamed material structure

12

s

having a plurality of slots

30

, and preferably, at least one polymeric foamed material opening

15

. Thus, and as best shown in

FIG. 19

, between the formation of two particular adjacent slots

30

, the polymeric foamed material opening

15

(including slot

70

) was cut; and between the formation of the left extreme slot

30

and right extreme slot

30

in

FIG. 19

(or the two opposed slots

30

respectively adjacent to channel

26

and tongue

24

in

FIG. 19

) the polymeric material opening

15

(including slot

70

) along with a slot

30

(i.e. the slot

30

between the left extreme slot

30

and the right extreme slot

30

) was cut or formed.

The slots

30

may be of any desired shape or configuration to receive a comparable shaped or configured stud or brace

14

. Preferably, the slots are generally C-shaped, as shown in FIG.

19

and FIG.

32

. Alternatively and preferably further, the slots

30

may be partially Z-shaped (see

FIG. 29

) to partially receive a Z-shaped brace

14

such that when a Z-shaped brace

14

is slid into the partially Z-shaped slot

30

, a portion of Z-shaped brace

14

protrudes away from the polymeric foamed material

12

, as best shown in FIG.

30

. The slots

30

may be partially C-shaped (see

FIG. 26

) to partially receive a C-shaped brace

14

such that when a C-shaped brace

14

is slid into the partially C-shaped slot

30

, a portion of the C-shaped brace

14

protrudes away from the polymeric foamed material

12

, as best shown in

FIGS. 27 and 28B

. The polymeric openings

15

are preferably cylindrical openings for receiving the conduits

19

.

After the slots

30

and polymeric openings

15

have been cut and the plurality of polymeric foamed material structures

12

s

have been produced (see

FIG. 19

) from the block

8

of polymeric foamed material

12

, the computer control assembly

200

preferably causes the wires

58

to be moved to cut a plurality of channels

26

in the side of the block

8

of the polymeric foamed material

12

opposed to the side

8

s

. Subsequently, the plurality of polymeric foamed material structures

12

s

, while remaining in a stacked or superimposed relationship, are rotated 90 degrees to posture the stacked polymeric foamed material structures

12

s

for formation of the track chases

100

and the transverse polymeric opening(s)

17

and

25

if desired. The wires

58

are moved by computer control assembly

200

such that the track chases

100

are formed in each of the polymeric foamed material structures

12

s

at any desired location, preferably at the location shown in FIGS.

25

-

31

. The transverse polymeric openings

17

may be formed in the respective polymeric foamed material structures

12

s

by passing each wire

58

in an initially cut path between any two superimposed polymeric foamed material structures

12

s

—

12

s

and either raising or lowering the wire

58

against the respective surface

74

(e.g. see

FIG. 10

) of a respective polymeric foamed material structure

12

s

and respective slots

70

are commenced to be cut by each of the hot wires

58

. The respective slots

70

s

are continually cut until respective points

72

(i.e. preconfiguration cut points

72

) are reached whereupon the computer

52

signals the hot wire cutter assembly

50

to move the hot wires

58

in a circular fashion or manner to cut and/or burn and/or melt back polymeric foamed material

12

such that when respective core materials

12

A are removed, the polymeric opening

17

is produced in each of the polymeric foamed material structures

12

s

with a respective slot

70

terminating in a respective polymeric opening

17

. As previously indicated, removal of the core material

12

A may be by any suitable means including manual removal of it. Polymeric openings

25

may be formed in the same manner after a core material (not shown, but similar to core material

12

A) has been removed. As was previously indicated, conduits

16

and internal reinforcing member

23

are to be respectively inserted into the polymeric openings

17

and into the polymeric openings

25

.

Referring now to FIGS.

19

-

25

for the procedure of cutting generally C-shaped slots

30

as shown in the respective polymeric foamed material structures

12

s

, the plurality of hot: wires

58

are moved by the computer control assembly

200

in direction of the arrow

300

(see

FIG. 20

) for a desired distance. The wires

58

are then moved in direction of the arrow

302

(which is preferably normal to the direction of the arrow

300

) for a distance which approximates the length of a flange return

14

r

of a generally C-shaped brace member

14

. Wires

58

are subsequently moved a predetermined distance L (see

FIG. 24

) in direction of the arrow

304

into an off-set position. The distance L is preferably equal to about the measurement of the diameter D (see

FIG. 23

) of one of the wires

58

. The direction of the arrow

304

is preferably a direction which is generally perpendicular to direction of arrow

302

. From the off-set position the wires

58

move in direction of the arrow

306

for a distance which is less than distance that the wires

58

moved when travelling in direction of the arrow

302

. When the wires

58

are travelling in direction of the arrow

306

, they are forming an off-set path next to the path that the wires

58

formed in travelling the direction of arrow

302

. The width W of the off-set path is approximately equal to twice the measurement of the diameter D of the wires

58

(see FIG.

24

).

After travelling a distance in direction of the arrow

306

which is less than the distance that the wires travelled in direction of the arrow

302

, the wires

58

travel in direction of the arrow

308

(see

FIG. 20

again). The direction of the arrow

308

is generally normal to the direction of the arrow

306

. After travelling a desired distance along a path in direction of the arrow

308

, the wires are then moved by the computer control assembly

200

in direction of the arrow

310

. It should be understood that the distance that the wires

58

travelled in direction of the arrow

308

is approximately equal to the length of a flange

14

f

of a generally C-shaped brace member

14

. The distance that the wires

58

travelled in direction of the arrows

308

is also approximately equal to the width of a polymeric material crest

12

c

(see FIG.

20

B), with the height of the polymeric material crest

12

c

resulting from the wires

58

travelling at a distance in direction of the arrow

306

that is less than the distance that the arrows travelled in direction of the arrows

302

. Polymeric material crest

12

c

also results from a polymeric material recess

12

r

being formed (see

FIG. 20B

again).

The wires

58

travel a distance in direction of the arrow

310

, which distance is approximately equal to the length of a web

14

f

of a generally C-shaped brace member

14

. From the direction of the arrow

310

, the wires

58

travel in direction of the arrow

312

for a distance that approximately equals the distance that the wires

58

travelled in direction of the arrow

308

. The direction of the arrow

312

is generally perpendicular to the direction of the arrow

310

. The wires

58

subsequently travel in direction of the arrow

314

for a distance that approximately equals the distance that the wires

58

travelled in direction of the arrow

306

. From direction of the arrow

314

, the wires

58

are then moved in direction of the arrow

316

for a predetermined distance which is preferably equal to the predetermined distance L (see FIG.

24

). The wires

58

are now in another off-set position. From this off-set position, the wires

58

generally retrace the path that the wires

58

cut when moving in direction of the arrows

310

,

312

and

314

. While retracing this path, the wires

58

remain in the off-set position. In retracing the path that the wires

58

made when moving in direction of the arrows

310

,

312

and

314

, the wires

58

move in direction of the arrows

318

,

320

and

322

, as best shown in FIG.

20

. The distance that the wires

58

travel in direction of the arrow

318

is generally equal to the distance that the wires

58

travelled when travelling in the direction of the arrow

302

. The direction of the arrow

320

is generally normal to the direction of arrows

318

and

322

. After having moved in direction of the arrows

318

,

320

and

322

to form an off-set path next to the path that the wires

58

formed when moving in direction of the arrows

310

,

312

, and

314

, the wires

58

then move in direction of the arrow

324

. The generally C-shaped slot

30

of

FIGS. 19

,

20

, and

25

has now been formed.

By the practice of the present invention there is provided a method for producing the polymeric foamed material panel

10

(e.g. a low density synthetic panel) comprising the steps of: (a) providing the polymeric foamed material

12

; (b) cutting (e.g. with one or more wires

58

) the polymeric foamed material

12

of step (a) until reaching the preconfiguration cut point

72

; (c) cutting subsequently from the preconfiguration cut point

72

the brace-receiving configuration (i.e. the slot

30

) in the polymeric foamed material

12

; and (d) sliding the brace member into the brace-receiving configuration (or the slot

30

) to produce the polymeric foamed material panel

10

. The cutting in step (b) and the cutting in step (c) comprises cutting the polymeric foamed material

12

of step (a) with the hot wire cutter assembly

50

which is preferably operated by the computer

52

. The cutters may also be laser cutters. If hot wires

58

are used as cutters for forming respective slots

30

, the walls or cut surfaces (i.e. cut surfaces

30

w

c

,

30

f

c

, and

30

r

1c

) would be seared surfaces. The brace-receiving configuration in the polymeric foamed material

12

preferably comprises the slot

30

for receiving the brace member

14

. The slot

30

includes at least one seared wall

32

for facilitating the sliding of the brace member

14

. The brace member

14

includes the opening

18

with an opening perimeter. The method additionally comprises forming the polymeric (foamed material) opening

17

in the polymeric foamed material

12

. The polymeric foamed material opening

17

has a polymeric foamed material opening perimeter. The sliding in step (d) comprises sliding the brace member

14

into the brace-receiving configuration until the opening

18

of the brace member

14

is generally aligned with the polymeric (foamed material) opening

17

. The opening perimeter of the opening

18

in the brace member

14

has a dimension that is greater than

4

dimension of the polymeric foamed material opening perimeter of the polymeric (foamed material) opening

17

in the polymeric foamed material

12

.

By the practice of the present invention there is further provided a method for forming a structure

40

comprising the steps of: (a) providing a first polymeric foamed material

12

having a first defined edge

20

(i.e. end

20

); (b) cutting a first brace-receiving-configured slot

30

in the first polymeric foamed material

12

; (c) cutting the first defined edge

20

of the first polymeric foamed material

12

to form the tongue

24

on the first defined edge

20

; (d) sliding a first brace member

14

into the first brace-receiving-configured slot

30

; (e) providing a second polymeric foamed material

12

having a second defined edge

22

(i.e. end

22

); (f) cutting a second brace-receiving-configured slot

30

in the second polymeric foamed material

12

; (g) cutting the second defined edge

22

of the second polymeric foamed material

12

to form the channel

26

in the second defined edge

22

; (h) sliding the second brace member

14

into the second brace-receiving-configured slot

30

; and (i) sliding the tongue

24

on the first defined edge

20

of the first polymeric foamed material

12

into the channel

26

in the second defined edge

22

of the second polymeric foamed material

12

to form the structure

40

.

By the further practice of the present invention there is also provided a polymeric foamed material panel

10

comprising a panel

10

consisting of the polymeric foamed material

12

; a brace-receiving-configured slot (i.e. slot

30

preferably) disposed in the polymeric foamed material

12

of the panel

10

and a brace member

14

disposed in the brace-receiving-configured slot

30

in the polymeric foamed material

12

of the panel

10

. The preferred brace-receiving-configured slot

30

includes at least one seared wall

32

; typically all walls of the slot

30

are seared. The polymeric foamed material panel

10

additionally comprises a generally straight thread-like slot

70

extending from a defined surface

74

of the polymeric foamed material

12

to the brace-receiving-configured slot

30

; and a second generally straight thread-like slot

70

extending from the defined surface

74

of the polymeric foamed material

12

to a generally cylindrical polymeric opening

17

in the polymeric foamed material

12

. All walls of the polymeric opening

17

are typically seared.

Practice of the present invention also provides method for producing a plurality of polymeric foamed material panels

10

comprising the steps of: (a) providing a block

8

of polymeric foamed material

12

; (b) cutting the polymeric foamed material

12

with a plurality of cutters (e.g. laser cutters or hot wires

58

) until each cutter reaches a respective preconfiguration cut point (i.e. preconfiguration cut point

72

); (c) cutting subsequently with each cutter from the respective preconfiguration cut point of each cutter a respective brace-receiving slot

30

in the polymeric foamed material

12

; (d) cutting then the polymeric foamed material

12

with the plurality of cutters to produce a plurality of polymeric foamed material structures

12

s

having a plurality of brace-receiving slots

30

; and (e) sliding a plurality of brace members

14

into the brace-receiving slots

30

of the polymeric foamed material structures

12

s

to produce a plurality of polymeric foamed material panels

10

, each of the polymeric foamed material panels

10

having at least one of the brace members

14

. This method additionally comprises cutting with each cutter a respective polymeric foamed material opening (e.g. opening

15

,

17

or

25

) in the polymeric foamed material

12

such that each polymeric foamed material structure

12

s

has a polymeric foamed material opening (e.g. opening

15

,

17

or

25

) to define a chase. The cutters are preferably computer operated to provide desired cut accuracy.

Another practice of the present invention provides a method for producing a plurality of polymeric foamed material panels

10

comprising the steps of: (a) providing a block

8

(e.g., a generally stationary block) of polymeric foamed material

12

(e.g., expanded polystyrene (EPS)); (b) cutting the polymeric foamed material

12

with a plurality of cutters (e.g., hot wire cutters, laser cutter, etc.) until each cutter reaches a respective preconfiguration cut point

72

; (c) cutting subsequently with each cutter from the respective preconfiguration cut point

72

of each cutter a respective brace-receiving slot

30

in the polymeric foamed material

12

; (d) cutting then the polymeric foamed material

12

with said plurality of cutters to produce a plurality of polymeric foamed material structures

12

s

having a plurality of brace-receiving slots

30

, which may be linear or nonlinear slots; and (e) sliding a plurality of brace members

14

into the brace-receiving slots

30

of the polymeric foamed material structures

12

s

to produce a plurality of polymeric foamed material panels

10

, each of the polymeric foamed material panels

10

having at least one of the brace members

14

. In the immediate foregoing method of the present invention, the brace members

14

include sides. More particularly, each of the brace members

14

preferably comprises the web

14

w

, the flanges

14

f

—

14

f

integrally bound to the web

14

w

, and the flange returns

14

r

—

14

r

integrally bound to the flanges

14

f

—

14

f

. The web

14

w

, the flanges

14

f

—

14

f

, and the flange returns

14

r

—

14

r

are surrounded by the polymeric foamed material

12

. Alternatively and as another embodiment of the present invention, a portion of at least one brace member

14

protrudes from each of the polymeric foamed material panels

10

. Therefore, the sliding step (e) in the immediate foregoing method more specifically comprises sliding one of the flanges

14

f

and flange return

14

r

associated therewith, and a portion of the web

14

w

of respective brace members

14

into respective brace-receiving slots

30

of the polymeric foamed material structures

12

s

to produce the plurality of polymeric foamed material panels

10

, with each of the polymeric foamed material panels

10

having the other flange

14

f

and the flange return

14

r

associated therewith, and a portion of the web

14

w

of at least one of the brace members

14

disposed outside thereof.

An alternative practice of the present invention provides a method for producing a plurality of polymeric foamed material structures

12

s

having slots

30

for receiving stud members

14

comprising the steps of: (a) cutting a polymeric foamed material

12

(e.g., a generally stationary block

8

of expanded polystyrene (ESP)) with a plurality of cutters, such as hot wire cutters or laser cutters, in a first direction (e.g. in direction of the arrow

300

in FIG.

20

); (b) cutting subsequently in a second direction (e.g. in direction of the arrow

302

or arrow

310

in

FIG. 20

) the polymeric foamed material

12

with the plurality of cutters until each cutter forms a first respective slot in the polymeric foamed material

12

; (c) cutting in the first direction the polymeric foamed material

12

with the plurality of cutters to produce a plurality of polymeric foamed material structures

12

s

having a plurality of first slots (e.g. slot sections

30

r

1

in

FIG. 20

including opposed cut surfaces

30

r

1c

—

30

r

1c

) which may be linear or nonlinear slots. The immediately foregoing method broadly additionally comprises cutting the polymeric foamed material

12

with the plurality of cutters until each cutter forms a second respective slot (e.g. slot section

30

s

in

FIG. 20

including opposed cut surfaces

30

w

c

—

30

w

c

) in the polymeric foamed material

12

. The immediate foregoing method more particularly additionally comprises cutting the polymeric foamed material

12

with the plurality of cutters until each cutter forms a respective recess (e.g. polymeric material recess

12

r

in

FIG. 20

including cut surface

12

r

c

) in the polymeric foamed material

12

; and subsequently cutting the polymeric foamed material

12

with the plurality of cutters until each cutter forms a second respective slot (e.g. slot sections

30

s

in

FIG. 20

including opposed cut surfaces

30

w

c

—

30

w

c

) in the polymeric foamed material

12

such that after cutting, a plurality of polymeric foamed material structures are produced having a plurality of first slots (e.g. slot sections

30

r

1

including opposed cut surfaces

30

r

1c

—

30

r

1c

) and a plurality of second slots (e.g. slot sections

30

s

including opposed cut surfaces

30

s

c

—

30

s

c

) and a plurality of recesses (e.g. polymeric material recesses

12

r

including cut surfaces

12

r

c

). A plurality of stud members

14

is provided wherein each of the stud members

14

comprises a web

14

w

, a first flange

14

f

integrally bound to the web

14

w

, a first flange return

14

r

integrally bound to the first flange

14

f

, a second flange

14

f

also integrally bound to the web

14

w

, and a second flange return

14

r

integrally bound to the second flange

14

f

. The stud members

14

are slid into the first and second slots and into the recesses of the polymeric foamed material structures

12

s

, such that after the sliding step, the first flange return

14

r

and the first flange

14

f

of each of the stud members

14

occupies respectively one of the first slots (e.g. slot sections

30

r

1

and against opposed cut surfaces

30

r

1c

and

30

r

1c

) and one of the recesses (e.g. polymeric material recess

12

r

and against cut surface

12

r

c

) of the polymeric foamed material structures

12

s

, and the web

14

w

, the second flange

14

f

and the second flange return

14

r

of each of the stud members

14

occupies one of the second slots (e.g. slot section

30

s

and against opposed cut surfaces

30

w

c

and

30

w

c

) of the polymeric foamed material structures

12

s

. The cutters are preferably computer operated to provide the desired cut accuracy during the cutting steps.

Other features in alternative practices of the present invention include interrupting the movement of a plurality of cutters in a first direction of travel to move the cutters in at least one direction of travel which differs from the first direction of travel in order to form one or more brace-receiving slots. These features are embodied in a method for producing a plurality of polymeric foamed material structures

12

s

having brace-receiving slots

30

comprising the steps of: (a) providing a block

8

of polymeric foamed material

12

; and (b) moving a plurality of cutters through the block

8

of polymeric foamed material in a first direction (e.g. in direction of arrow

300

in

FIG. 20

) of travel, while interrupting at least one time the moving of the plurality of cutters in the first direction of travel to move the cutters through the block

8

of polymeric foamed material

12

in at least one direction of travel (e.g. in direction of arrow

302

or arrow

310

in

FIG. 20

) which differs from the first direction of travel, such that each cutter produces a respective brace-receiving slot

30

in the polymeric foamed material

12

, until the plurality of cutters have moved completely through the block

8

of polymeric foamed material

12

to produce a plurality of polymeric foamed material structures

12

s

with each structure

12

s

having at least one brace-receiving slot (e.g. slot sections

30

s

and/or

30

r

1

in FIG.

20

and respectively including opposed cut surfaces

30

w

c

and

30

w

c

and/or including opposed cut surfaces

30

r

1c

and

30

r

1c

). These features are also embodied in a method for producing a plurality of polymeric foamed material structures

12

s

having brace-receiving slots comprising the steps of: (a) providing a block

8

of polymeric foamed material

12

in a generally stationary position; (b) moving a plurality of cutters through the generally stationary block

8

of polymeric foamed material

12

in a first direction of travel (e.g. in direction of arrow

300

in FIG.

20

); (c) interrupting the movement of the plurality of cutters from the first direction of travel through the generally stationary block

8

of polymeric foamed material

12

to move the cutters in at least one direction of travel (e.g. in direction of the arrow

302

in

FIG. 20

) which differs from the first direction of travel such that each cutter produces a respective brace-receiving slot (e.g. slot section

30

r

1

in

FIG. 20

including opposed cut surfaces

30

r

1c

and

30

r

1c

) in the polymeric foamed material

12

, and (d) continuing the moving of the plurality of cutters in the first direction of travel, while intermittently interrupting the movement of the plurality of cutters from the first direction of travel to move the cutters in at least one direction of travel (e.g. in direction of the arrow

310

in

FIG. 20

) which differs from the first direction of travel such that each cutter produces at least one additional respective brace-receiving slot (e.g. slot section

30

s

in

FIG. 20

including opposed cut surfaces

30

w

c

and

30

w

c

) in the polymeric foamed material

12

, until the plurality of cutters have moved completely through the generally stationary block

8

of polymeric foamed material

12

after which a plurality of polymeric foamed material structures

12

s

are produced with each polymeric foamed material structure

12

s

having a plurality of brace-receiving slots (e.g. slot sections

30

s

and/or

30

r

1

in FIG.

20

and respectively including opposed cut surfaces

30

w

c

and

30

w

c

and/or including opposed cut surfaces

30

r

1c

and

30

r

1c

).

In additional practices of the present invention there is broadly provided a method for producing a polymeric foamed material structure

12

s

having a slot (e.g. slot section

30

r

1

in

FIG. 20

including opposed cut surfaces

30

r

1c

and

30

r

1c

) comprising the steps of: (a) cutting with a cutter a polymeric foamed material

12

until reaching a preslot cut point (e.g. the point where the hot wire

58

stops after being moved in direction of the arrow

300

in FIG.

20

); (b) cutting subsequently a first path in the polymeric foamed material

12

with the cutter from the preslot cut point until reaching a first cut point (e.g. the point where the hot wire

58

stops after being moved in direction of the arrow

302

in FIG.

20

); (c) moving the cutter in the polymeric foamed material

12

a predetermined distance (e.g. distance L in

FIG. 24

) from the first cut point to a second cut point (e.g. the point where the hot wire

58

stops after being moved in direction of the arrow

304

in FIGS.

20

and

24

); and (d) cutting subsequently from the second cut point a second path (e.g. an off-set path) in the polymeric foamed material

12

with the cutter until the cutter reaches a postslot cut point (e.g. the point where the hot wire

58

stops after being moved in direction of the arrow

306

in

FIGS. 20 and 24

) to produce a polymeric foamed material structure

12

s

having a slot (e.g. slot section

30

r

1

in

FIG. 20

including opposed cut surfaces

30

r

1c

and

30

r

1c

). In the immediate foregoing method of the present invention, the cutter is preferably a computer-operated hot wire cutter having a wire diameter D with a generally known diameter measurement, and the slot (e.g. slot section

30

r

1

in

FIG. 20

) has a width W equal to about twice the generally known diameter measurement of the wire diameter D, and a width W equal to about twice the predetermined distance (e.g. distance L in FIG.

24

).

Further additional practices of the present invention broadly provide a method for producing at least one polymeric foamed material structure

12

s

having at least one slot (e.g. slot section

30

s

in

FIG. 20

including opposed cut surfaces

30

w

c

and

30

w

c

) comprising the steps of: (a) providing at least one cutter; (b) cutting with the cutter a polymeric foamed material

12

until the cutter reaches at least one respective preslot cut point (e.g. the point where the hot wire

58

stops after being moved in direction of the arrow

308

in FIG.

20

); (c) cutting subsequently with cutter from the respective preslot cut point at least one respective path in is the polymeric foamed material

12

until the cutter reaches at least one first cut point (e.g. the point where the hot wire

58

stops after being moved in direction of the arrows

310

,

312

and

314

in FIG.

20

); (d) forming with the cutter in the polymeric foamed material

12

at least one respective off-set path (e.g. the path taken by hot wire

58

in moving in direction of the arrows

318

,

320

and

322

in

FIG. 20

) communicating with the respective path to form at least one slot (e.g. slot section

30

s

in

FIG. 20

including opposed cut surfaces

30

w

c

and

30

w

c

) within the polymeric foamed material

12

; and (e) cutting subsequently the polymeric foamed material

12

with the cutter (e.g. in direction of the arrow

324

in

FIG. 20

) until the cutter has cut through the polymeric foamed material

12

, producing at least one polymeric foamed structure

12

s

having at least one slot (e.g. slot section

30

s

in

FIG. 20

including opposed cut surfaces

30

w

c

and

30

w

c

). In the immediate foregoing method, the at least one respective path has at least one respective path length, and the at least one respective off-set path communicates with the at least one respective path along the at least one respective path length of the at least one respective path, such that the at least one respective path and the least one respective off-set path together form the at least one slot (e.g. slot section

30

s

in

FIG. 20

including opposed cut surfaces

30

w

c

and

30

w

c

) within the polymeric foamed material

12

.

Thus, practice of the present invention provides one or more polymeric foamed material panel(s)

10

which may be processed into any suitable blocks, for example, 4 feet by 4 feet by 24 feet. These blocks of polymeric foamed material

12

have been hot wired cut into an associated desired thickness as needed by the laminator/panel manufacturer. The polymeric foamed material panel(s)

10

of the present invention preferably encapsulate metal studs or braces

14

(as well as rafters if desired) in order to eliminate the need for plywood or OSB skins and the adhesives currently required in panel production. The metal studs

14

and rafters supply the structural engineering strength requirements.

The polymeric foamed material panel

10

becomes a pre-engineered “system” for building structures including, but not limited to, homes, apartments and commercial buildings or structures, as represented by structure(s)

40

in

FIGS. 2 and 2A

. The polymeric foamed material panel(s)

10

of the present invention is an improvement over the prior art in that they become the structure, the insulation, and the substrate for the interior and exterior finishes. The polymeric foamed material panel(s)

10

and the method of the present invention are also an improvement over the prior art in that they provide a market ready product at a significantly lower cost by eliminating secondary processing steps. The polymeric foamed material panel(s)

10

may be used in tandem with traditional Stress Skin and Structural Panels when attachment of a specific product (e.g. asphalt shingles, etc.) to the panel(s)

10

requires a solid wood substrate.

While the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure, and it will be appreciated that in some instances some features of the invention will be employed without a corresponding use of other features without departing from the scope and spirit of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments and equivalents falling within the scope of the appended claims.

Claims

1. A method for producing a plurality of polymeric foamed material structures having seared surfaces for contacting brace members comprising the steps of:a) providing a block of polymeric foamed material having a side and a pair of opposed ends; b) cutting the block of polymeric foamed material with a plurality of hot wire cutters in a first direction generally perpendicular from said side of said block of polymeric foamed material; c) cutting, immediately after said cutting step (b), the block of polymeric foamed material with the plurality of hot wire cutters in a second direction generally perpendicular from said first direction until each hot wire cutter forms in the polymeric foamed material a first respective cut seared surface terminating in said opposed ends of said block of polymeric foamed material; d) cutting, immediately after said cutting step (c), the block of polymeric foamed material with the plurality of hot wire cutters in a third direction generally perpendicular from said second direction until each hot wire cutter forms in the polymeric foamed material a second respective cut seared surface terminating in said opposed ends of said block of said polymeric foamed material; e) cutting the block of polymeric foamed material with the plurality of hot wire cutters in a fourth direction until each hot wire cutter forms in the polymeric foamed material a third respective cut seared surface terminating in said opposed ends of said block of polymeric foamed material; f) cutting the block of polymeric foamed material with the plurality of hot wire cutters in a fifth direction until each hot wire cutter forms in the polymeric foamed material a fourth respective cut seared surface terminating in said opposed ends of said block of polymeric foamed material; and g) cutting the block of polymeric foamed material with the plurality of hot wire cutters in a sixth direction to produce a plurality of polymeric foamed material structures, each of said polymeric foamed material structures having a first cut seared surface and a second cut seared surface for contacting a first brace member and a third cut seared surface and a fourth cut seared surface for contacting a second brace member.
2. The method of claim 1 additionally comprising cutting the block of polymeric foamed material with the plurality of hot wire cutters between said cutting step (d) and said cutting step (e).
3. The method of claim 2 additionally comprising cutting the block of polymeric foamed material with the plurality of hot wire cutters such that each of said polymeric foamed material structures has a tongue member and a channel member.
4. The method of claim 3 wherein said cutting step (g) is after said cutting step (f).
5. The method of claim 2 additionally comprising computer operating said hot wire cutters; and said block of polymeric foamed material is generally stationary; and said cutting step (c) additionally producing an opposed first respective cut seared surface terminating in said opposed ends of said block of polymeric foamed material and opposed to said first respective cut seared surface to form a first slot in each of said polymeric foamed material structures; and said cutting step (d) additionally producing an opposed second respective cut seared surface terminating in said opposed ends of said block of polymeric foamed material and opposed to said second respective cut seared surface to form a second slot in each of said polymeric foamed material structures, each of said polymeric foamed material structures having said first slot and said second slot for receiving a first brace member; and said cutting step (e) additionally producing an opposed third respective cut seared surface terminating in said opposed ends of said block of polymeric foamed material and opposed to said third respective cut seared surface to form a third slot in each of said polymeric foamed material structures; and said cutting step (f) additionally producing an opposed fourth respective cut seared surface terminating in said opposed ends of said block of polymeric foamed material and opposed to said fourth respective cut seared surface to form a fourth slot in each of said polymeric foamed material structures, each of said polymeric foamed material structures having said third slot and said fourth slot for receiving a second brace member.
6. The method of claim 1 additionally comprising cutting the block of polymeric foamed material with the plurality of hot wire cutters such that each of said polymeric foamed material structures has a tongue member and a channel member.
7. The method of claim 1 wherein said cutting step (f) is before said cutting step (e).
8. The method of claim 7 additionally comprising computer operating said hot wire cutters; and said block of polymeric foamed material is generally stationary; and said fifth direction is generally perpendicular from said fourth direction; and said sixth direction is generally perpendicular from said fifth direction.
9. The method of claim 7 additionally comprising forming a first flage-return slot, a second flange-return slot, a third flange-return slot, and a fourth flange-return slot in each of the polymeric foamed material structures.
10. The method of claim 9 additionally comprising providing a plurality of first brace members wherein each of said first brace members comprises a first web, a first flange secured to said first web, a first flange return secured to said first flange, a second flange secured to said web, and a second flange return secured to said second flange; and additionally comprising providing a plurality of second brace members wherein each of said second brace members comprises a second web, a third flange secured to said second web, a third flange return secured to said third flange, a fourth flange secured to said second web, a fourth flange return secured to said fourth flange; and disposing the plurality of the first brace members and the plurality of the second brace members in the plurality of polymeric foamed material structures such that each of said polymeric foamed material structures comprises the first web of the first brace member positioned against the first cut seared surface, the first flange positioned against the second cut secured surface, the first flange return positioned in the first flange-return slot, the second flange return positioned in the second flange-return slot, the second web of the second brace member positioned against the fourth cut seared surface, the third flange positioned against the third cut seared surface, the third flange return positioned in the third flange-return slot, and the fourth flange return positioned in the fourth flange-return slot.
11. A plurality of polymeric foamed material structures produced in accordance with the method of claim 10.
12. The method of claim 1 additionally comprising forming a first flange-return slot, a second flange-return slot, a third flange-return slot, and a fourth flange-return slot in each of the polymeric foamed material structures.
13. The method of claim 12 additionally comprising providing a plurality of first brace members wherein each of said first brace members comprises a first web, a first flange secured to said first web, a first flange return secured to said first flange, a second flange secured to said web, and a second flange return secured to said second flange; and additionally comprising providing a plurality of second brace members wherein each of said second brace members comprises a second web, a third flange secured to said second web, a third flange return secured to said third flange, a fourth flange secured to said second web, a fourth flange return secured to said fourth flange; and disposing the plurality of the first brace members and the plurality of the second brace members in the plurality of polymeric foamed material structures such that each of said polymeric foamed material structures comprises the first web of the first brace member positioned against the first cut seared surface, the first flange positioned against the second cut secured surface, the first flange return positioned in the first flange-return slot, the second flange return positioned in the second flange-return slot, the second web of the second brace member positioned against the fourth cut seared surface, the third flange positioned against the third cut seared surface, the third flange return positioned in the third flange-return slot, and the fourth flange return positioned in the fourth flange-return slot.
14. The method of claim 13 additionally comprising cutting the block of polymeric foamed material prior to said cutting step (g).
15. The method of claim 13 additionally comprising cutting the block of polymeric foamed material after said cutting step (g) and prior to disposing the plurality of the first brace members and the plurality of the second brace members in the plurality of polymeric foamed material structures.
16. A plurality of polymeric foamed material structures produced in accordance with the method of claim 13.
17. A plurality of polymeric foamed material structures produced in accordance with the method of claim 1.
18. A method for producing a polymeric foamed material panel comprising the steps of:a) providing a polymeric foamed material structure comprising a pair of opposed ends, a side surface, a first hotwire-cut seared surface having been cut by a hotwire cutter in a first direction relative to said side surface and terminating in said pair of opposed ends, a second hotwire-cut seared surface having been cut by a hotwire cutter in a second direction from said first hotwire-cut seared surface and terminating in said pair of opposed ends, and a third hotwire-cut seared surface having been cut by a hotwire cutter in a third direction from said second hotwire-cut seared surface and terminating in said pair of opposed ends; b) providing a brace member having a web and at least one flange secured to the web; and c) disposing respectively the web and the flange of the brace member against the second hotwire-cut seared surface and the third hotwire-cut seared surface to produce a polymeric foamed material panel.
19. The method of claim 18 wherein said first direction is generally perpendicular to said side surface.
20. The method of claim 18 wherein said brace member comprises a generally C-shape.
21. The method of claim 20 wherein a portion of the web of the brace member protrudes from the polymeric foamed material panel.
22. The method of claim 18 wherein said brace member comprises a generally Z-shape.
23. A polymeric foamed material panel produced in accordance with the method of claim 18.
24. A method for forming a structure comprising the steps of:a) cutting a first polymeric foamed material with a first cutter in a first direction relative to a first side surface of the first polymeric foamed material; b) cutting with the first cutter the first polymeric foamed material in a second direction relative to the first direction to produce a first-cutter first cut surface terminating in opposed ends of said first polymeric foamed material; c) cutting with the first cutter the first polymeric foamed material in a third direction relative to the second direction to produce a first-cutter second cut surface terminating in said opposed ends of said first polymeric foamed material; d) cutting the first polymeric foamed material with the first cutter to produce a first tongue in the first polymeric foamed material; e) providing a first brace member having a first web and at least one first flange secured to the first web; f) disposing respectively the first web and the first flange of the first brace member against the first-cutter first cut surface of step (b) and the first-cutter second cut surface of step (c) to produce a first polymeric foamed material panel having said first tongue; g) cutting a second polymeric foamed material with a second cutter to produce a second channel in the second polymeric foamed material; h) cutting the second polymeric foamed material with the second cutter in a first direction relative to a second side surface of the second polymeric foamed material; i) cutting with the second cutter the second polymeric foamed material in a second direction relative to the first direction to produce a second-cutter first cut surface terminating in opposed ends of said second polymeric foamed material; j) cutting with the second cutter the second polymeric foamed material in a third direction relative to the second direction to produce a second-cutter second cut surface terminating in said opposed ends of said second polymeric foamed material; k) providing a second brace member having a second web and at least one second flange secured to the second web; l) disposing respectively the second web and the second flange of the second brace member against the second-cutter first cut surface of step (i) and the second-cutter second cut surface of step (j) to produce a second polymeric foamed material panel having said second channel; and m) sliding said first tongue of said first polymeric foamed material panel into said second channel of said second polymeric foamed material panel to form a structure.
25. The method of claim 24 additionally comprising cutting the first polymeric foamed material with the first cutter to produce a first channel in the polymeric foamed material and cutting the second polymeric foamed material with the second cutter to produce a second tongue in the second polymeric foamed material.
26. The method of claim 25 wherein said first direction of step (a) is generally perpendicular to the first side surface of step (a); said second direction of step (b) is generally perpendicular to said first direction of step (a); said third direction step (c) is generally perpendicular to said second direction of step (b); and wherein said first direction of step (h) is generally perpendicular to the second side surface of step (h); said second direction of step (i) is generally perpendicular to said first direction of step (h); said third direction of step (j) is generally perpendicular to said second direction of step (i).
27. The method of claim 24 wherein said first direction of step (a) is generally perpendicular to the first side surface of step (a); said second direction of step (b) is generally perpendicular to said first direction of step (a); said third direction step (c) is generally perpendicular to said second direction of step (b); and wherein said first direction of step (h) is generally perpendicular to the second side surface of step (h); said second direction of step (i) is generally perpendicular to said first direction of step (h); said third direction of step (j) is generally perpendicular to said second direction of step (i).
28. The method of claim 24 additionally comprising cutting respectively said first polymeric foamed material with said first cutter in said cutting steps (a) through (d) generally simultaneously with cutting respectively said second polymeric foamed material with said second cutter in said cutting steps (g) through (j).
29. The method of claim 24 wherein said cutting step (b) additionally producing an opposed first-cutter first cut surface terminating in said opposed ends of said first polymeric foamed material and opposed to said first-cutter first cut surface to form a first-cutter first slot in said first polymeric foamed material; and said cutting step (c) additionally producing an opposed first-cutter second cut surface terminating in said opposed ends of said first polymeric foamed material and opposed to said first-cutter second cut surface to form a first-cutter second slot in said first polymeric foamed material such that after said disposing step (f) said first web and said first flange of said first brace member are further disposed respectively in said first-cutter first slot and in said first-cutter second slot; and said cutting step (i) additionally producing an opposed second-cutter first cut surface terminating in said opposed ends of said second polymeric foamed material and opposed to said second-cutter first cut surface to form a second-cutter first slot in said second polymeric foamed material; and said cutting step (j) additionally producing an opposed second-cutter second cut surface terminating in said opposed ends of said second polymeric foamed material and opposed to said second-cutter second cut surface to form a second-cutter second slot in said second polymeric foamed material such that after said disposing step (l) said second web and said second flange of said second brace member are further disposed respectively in said second-cutter first slot and in second-cutter second slot.
30. The method of claim 24 wherein said second cutter and said first cutter are respectively a cutter selected from the group consisting of a hotwire cutter and a laser cutter.
31. The method of claim 24 wherein said first brace member comprises a generally C-shape, and a portion of the first web of the first brace member protrudes from the first polymeric foamed material panel.
32. A structure produced in accordance with the method of claim 24.
33. A method for forming a structure comprising the steps of:a) providing a first polymeric foamed material structure comprising a pair of opposed first ends, a first defined side surface, a first tongue, a first hotwire-cut seared surface having been cut by a hotwire cutter in a first direction relative to said first defined side surface and terminating in said pair of opposed first ends, a second hotwire-cut seared surface having been cut by a hotwire cutter in a second direction from said first hotwire-cut seared surface and terminating in said pair of opposed first ends, and a third hotwire-cut seared surface having been cut by a hotwire cutter in a third direction from said second hotwire-cut seared surface and terminating in said pair of opposed first ends; b) providing a first brace member having a first web and at least one first flange secured to the web; c) disposing respectively the first web and the first flange of the first brace member against the second hotwire-cut seared surface of step (a) and the third hotwire-cut seared surface of step (a) to produce a first polymeric foamed material panel having said first tongue; d) providing a second polymeric foamed material structure comprising a pair of opposed second ends, a second defined side surface, a second channel, a first hotwire-cut seared surface having been cut by a hotwire cutter in a first direction relative to said second defined side surface and terminating in said pair of opposed second ends, a second hotwire-cut seared surface having been cut by a hotwire cutter in a second direction from said first hotwire-cut seared surface and terminating in said pair of opposed second ends, and a third hotwire-cut seared surface having been cut by a hotwire cutter in a third direction from said second hotwire-cut seared surface and terminating in said pair of opposed second ends; e) providing a second brace member having a second web and at least one second flange secured to the web; f) disposing respectively the second web and the second flange of the second brace member against the second hotwire-cut seared surface of step (d) and the third hotwire-cut seared surface of step (d) to produce a second polymeric foamed material panel having said second channel; and g) disposing said first tongue of said first polymeric foamed material panel into said second channel of said second polymeric foamed material panel to form a structure.
34. A structure formed in accordance with the method of claim 33.
35. A method for producing a plurality of polymeric foamed material panels comprising the steps of:a) cutting a polymeric foamed material with a plurality of cutters in a generally perpendicular direction from a defined surface of the polymeric foamed material; b) cutting in at least a second direction the polymeric foamed material of step (a) with the plurality of cutters until each cutter forms in the polymeric foamed material a first respective slot terminating in opposed ends of the polymeric foamed material; c) cutting with the plurality of cutters the polymeric foamed material of step (b) in said generally perpendicular direction of step (a) to produce a plurality of polymeric foamed material structures having first slots; and d) disposing first brace members in the first slots of the polymeric foamed material structures of step (c) to produce a plurality of polymeric foamed material panels with each polymeric foamed material panel having one of said first brace members.
36. The method of claim 35 wherein said first brace members each comprise a generally C-shape, and said defined surface is a side of said polymeric foamed material.
37. The method of claim 36 wherein each of first brace members include a web a portion which protrudes from said polymeric foamed material panel.
38. A plurality of polymeric foamed material panels produced in accordance with the method of claim 35.
39. The method of claim 35 additionally comprising cutting the polymeric foamed material with the plurality of cutters until each cutter forms a second respective slot in the polymeric foamed material and said produced plurality of polymeric foamed material structures include second slots.
40. The method of claim 39 additionally comprising disposing second brace members in the second slots of the produced polymeric foamed material structures such that each polymeric foamed material panel includes one of said second brace members.
41. A method for producing a plurality of polymeric foamed material panels comprising the steps of:a) providing a block of polymeric foamed material in a generally stationary position having a defined surface and a pair of opposed ends; b) moving from said defined surface a plurality of cutters through the generally stationary block of polymeric foamed material of step (a) in a generally perpendicular direction of travel; c) interrupting the movement of the plurality of cutters from said generally perpendicular direction of travel through the generally stationary blocks of polymeric foamed material to move the cutters in at least one direction of travel which differs from said generally perpendicular direction of travel such that each cutter produces a respective brace-receiving slot in the polymeric foamed material terminating in said opposed ends; d) continuing said moving step (b) of said plurality of cutters in said generally perpendicular direction of travel, while intermittently interrupting the movement of the plurality of cutters from generally perpendicular direction of travel to move the cutters in at least one direction of travel which differs from said generally perpendicular direction of travel such that each cutter produces at least one additional respective brace-receiving slot in the polymeric foamed material, until said plurality of cutters have moved completely through the generally stationary block of polymeric foamed material after which a plurality of polymeric foamed material structures are produced with each polymeric foamed material structure having a plurality of brace-receiving slots; and e) disposing brace members into the brace-receiving slots of the polymeric foamed material structures of step (d) to produce a plurality of polymeric foamed material panels with each polymeric foamed material panel having two of said brace members.
42. A plurality of polymeric foamed material panels produced in accordance with the method of claim 41.
43. The method of claim 41 wherein said defined surface comprises a side of said block of polymeric foamed material.
44. A method for producing a plurality of polymeric foamed material panels comprising the steps of:a) cutting a polymeric foamed material in a first direction with a plurality of cutters generally moving in unison; b) cutting subsequently the polymeric foamed material of step (a) in a second direction with said plurality of cutters generally moving in unison; c) cutting, after said cutting step (b), the polymeric foamed material of step (b) in said first direction with said plurality of cutters generally moving in unison; d) cutting, after said cutting step (c), the polymeric foamed material of step (c) in a third direction with said plurality of cutters generally moving in unison; e) cutting, after said cutting step (d), the polymeric foamed material of step (d) in said first direction with said plurality of cutters generally moving in unison until said cutters have cut through the polymeric foamed material of step (d) to produce a plurality of polymeric foamed material structures having brace-receiving configurations; and f) sliding brace members into the brace-receiving configurations of said polymeric foamed material structures of step (e) to produce a plurality of polymeric foamed material panels with each polymeric foamed material panel having one of said brace members.
45. A plurality of polymeric foamed material panels produced in accordance with the method of claim 44.
46. A method for producing a plurality of polymeric foamed material panels comprising the steps of:a) providing a block of polymeric foamed material having a defined surface and a pair of opposed ends; b) moving from said defined surface a plurality of cutters through the block of polymeric foamed material in a generally perpendicular direction of travel, while interrupting at least one time the moving of the plurality of cutters in said generally perpendicular direction of travel to move the cutters through the block of polymeric foamed material in at least one direction of travel which differs from said generally perpendicular direction of travel, such that each cutter produces a respective brace-receiving slot in the polymeric foamed material terminating in said opposed ends, until said plurality of cutters have moved completely through the block of polymeric foamed material to produce a plurality of polymeric foamed material structures with each structure having at least one brace-receiving slot; and c) disposing a brace member into each brace-receiving slot of said polymeric foamed material structures to produce a plurality of polymeric foamed material panels with each of said polymeric foamed material panels having at least one brace member.
47. The method of claim 46 wherein said defined surface is a side surface of said block of polymeric foamed material.
48. A plurality of polymeric foamed material panels produced in accordance with the method of claim 46.
49. A method for producing a plurality of polymeric foamed material structures having slot sections for receiving stud members comprising the steps of:a) cutting a polymeric foamed material with a plurality of cutters in a generally perpendicular direction from a side of the polymeric foamed material; b) cutting subsequently in at least a second direction the polymeric foamed material of step (a) with the plurality of cutters until each cutter forms a first respective slot section in the polymeric foamed material, said first respective slot section terminating in opposed ends of the polymeric foamed material; and c) cutting in said generally perpendicular direction of step (a) the polymeric foamed material with the plurality of cutters to produce a plurality of polymeric foamed material structures having a plurality of first slot sections, with each polymeric foamed material structure having one of the first slot sections.
50. The method of claim 49 wherein said plurality of cutters move generally simultaneously.
51. The method of claim 50 wherein said polymeric foamed material of step (a), step (b) and step (c) is generally stationary.
52. The method of claim 51 wherein said at least one second direction comprises a second direction generally perpendicular to said generally perpendicular direction of step (a).
53. The method of claim 52 additionally comprising cutting with the plurality of cutters, before said cutting step (c) and after said cutting step (b), the polymeric foamed material in said generally perpendicular direction of step (a) until each cutter forms a second respective slot section in the polymeric foamed material, said second respective slot section communicating with said first perspective slot section and terminating in opposed ends of the polymeric foamed material; and said cutting step (c) subsequently produces a plurality of polymeric foamed material structures having a plurality of first slot sections and a plurality of second slot sections, with each polymeric foamed material structure having one of the first slot sections and one of the second slot sections.
54. The method of claim 53 additionally comprising computer operating said plurality of cutters, and said plurality of cutters are selected from the group consisting of hot wire cutters and laser cutters.
55. The method of claim 52 additionally comprising cutting with the plurality of cutters, before said cutting step (c) and after said cutting step (b), the polymeric foamed material in said generally perpendicular direction of step (a) and subsequently in a fourth direction until each cutter forms a second respective slot section and a third respective slot section in the polymeric foamed material, said second respective slot section communicating with said first respective slot section and terminating in opposed ends of the polymeric foamed material and said third respective slot section communicating with said second respective slot section and terminating in opposed ends of the polymeric foamed material; and said cutting step (c) subsequently produces a plurality of polymeric foamed material structures having a plurality of first slot sections, a plurality of second slot sections, and a plurality of third slot sections, with each polymeric foamed material structure having one of the first slot sections, one of the second slot sections, and one of the third slot sections.
56. The method of claim 55 additionally comprising computer operating said plurality of cutters, and said plurality of cutters are selected from the group consisting of hot wire cutters and laser cutters.
57. The method of claim 55 additionally comprising providing a plurality of stud members, and disposing the plurality of stud members in said first slot sections and in said second slot sections and in said third slot sections of said polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each of the polymeric foamed material panels having one of the stud members respectively occupying the first slot section, the second slot section and the third slot section associated with said each of the polymeric foamed material panels.
58. The method of claim 57 additionally comprising computer operating said plurality of cutters, and said plurality of cutters are selected from the group consisting of hot wire cutters and laser cutters.
59. The method of claim 49 wherein said polymeric foamed material of step (a), step (b) and step (c) is generally stationary.
60. The method of claim 49 wherein said at least one second direction comprises a second direction generally perpendicular to said generally perpendicular direction of step (a).
61. The method of claim 49 additionally comprising cutting with the plurality of cutters, before said cutting step (c) and after said cutting step (b), the polymeric foamed material in said generally perpendicular direction of step (a) until each cutter forms a second respective slot section in the polymeric foamed material, said second respective slot section communicating with said first perspective slot section and terminating in opposed ends of the polymeric foamed material; and said cutting step (c) subsequently produces a plurality of polymeric foamed material structures having a plurality of first slot sections and a plurality of second slot sections, with each polymeric foamed material structure having one of the first slot sections and one of the second slot sections.
62. The method of claim 61 additionally comprising providing a plurality of stud members, and disposing the plurality of stud members in said first slot sections and in said second slot sections of said polymeric foamed material structures to provide a plurality of polymeric foamed material panels, with each polymeric foamed material panel having one of the stud members.
63. A plurality of polymeric foamed material panels produced in accordance with the method of claim 62.
64. The method claim 49 additionally comprising cutting with the plurality of cutters, before said cutting step (c) and after said cutting step (b), the polymeric foamed material in said generally perpendicular direction of step (a) and subsequently in a fourth direction until each cutter forms a second respective slot section and a third respective slot section in the polymeric foamed material, said second respective slot section communicating with said first respective slot section and terminating in opposed ends of the polymeric foamed material and said third respective slot section communicating with said second respective slot section and terminating in opposed ends of the polymeric foamed material; and said cutting step (c) subsequently produces a plurality of polymeric foamed material structures having a plurality of first slot sections, a plurality of second slot sections, and a plurality of third slot sections, with each polymeric foamed material structure having one of the first slot sections, one of the second slot sections, and one of the third slot sections.
65. The method of claim 64 additionally comprising providing a plurality of stud members, and disposing the plurality of stud members in said first slot sections and in said second slot sections and in said third slot sections of said polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each of the polymeric foamed material panels having one of the stud members respectively occupying the first slot section, the second slot section and the third slot section associated with said each of the polymeric foamed material panels.
66. A plurality of polymeric foamed material panels produced in accordance with the method of claim 65.
67. The method of claim 49 wherein said plurality of cutters comprise hot wire cutters.
68. The method of claim 67 additionally comprising computer operating said plurality of hot wire cutters.
69. The method of claim 49 wherein said plurality of cutters comprise laser cutters.
70. The method of claim 69 additionally comprising computer operating said plurality of laser cutters.
71. The method of claim 49 additionally comprising providing a plurality of stud members, and disposing the plurality of stud members in said first slot sections of said polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each polymeric foamed material panel having one of the stud members.
72. The plurality of polymeric foamed material structures produced in accordance with the method of claim 71.
73. A plurality of polymeric foamed material structures produced in accordance with the method of claim 49.
74. A method for producing a plurality of polymeric foamed material structures having slots for receiving stud members comprising the steps of:a) cutting a polymeric foamed material with a plurality of cutters in a generally perpendicular direction from a side surface of the polymeric foamed material; b) cutting subsequently in at least a second direction the polymeric foamed material of step (a) with the plurality of cutters until each cutter forms a first respective slot in the polymeric foamed material, said first respective slot terminating in opposed ends of the polymeric foamed material; c) cutting in said generally perpendicular direction of step (a) the polymeric foamed material with the plurality of cutters to produce a plurality of polymeric foamed material structures having a plurality of first slots, with each polymeric foamed material structure having one of the first slots.
75. The method of claim 74 additional comprising cutting, prior to said cutting step (c) and after said cutting step (b), the polymeric foamed material with the plurality of cutters until each cutter forms a second respective slot in the polymeric foamed material, said second respective slot terminating in opposed ends of the polymeric foamed material; and said cutting step (c) subsequently producing a plurality of polymeric foamed material structures having a plurality of first slots and a plurality of second slots, with each polymeric foamed material structure having one of the first slots and one of the second slots.
76. The method of claim 75 additionally comprising computer operating said plurality of cutters, and said plurality of cutters are selected from the group consisting of hot wire cutters and laser cutters.
77. The method of claim 76 wherein said polymeric foamed material is generally stationary and said plurality of cutters generally move simultaneously.
78. The method of claim 77 additionally comprising providing a plurality of stud members wherein each of said stud members comprises a web and a flange integrally bound to said web; and disposing the plurality of stud members in said first slots and in said second slots of said polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each of the polymeric foamed material panels having the web and the flange of one of the stud members respectively occupying the first slot and the second slot associated with said each of the polymeric foamed material panels.
79. A plurality of polymeric foamed material panels produced in accordance with the method of claim 78.
80. The method of claim 74 additionally comprising computer operating said plurality of cutters, and said plurality of cutters are selected from the group consisting of hot wire cutters and laser cutters.
81. A plurality of polymeric foamed material structures produced in accordance with the method of claim 74.
82. A method for producing a plurality of polymeric foamed material structures having brace-receiving slots comprising the steps of:a) providing a generally stationary block of polymeric foamed material having a side surface and a pair of opposed ends; b) moving generally simultaneously from said side surface a plurality of cutters through the block of polymeric foamed material in a generally perpendicular direction of travel, while interrupting at least one time the moving of the plurality of cutters in said generally perpendicular direction of travel to move the cutters through the block of polymeric foamed material in at least one direction of travel comprising a direction which differs from said generally perpendicular direction of travel, such that each cutter produces a respective brace-receiving slot in the polymeric foamed material terminating in said opposed end, until said plurality of cutters have moved completely through the, generally stationary block of polymeric foamed material to produce a plurality of polymeric foamed material structures having a plurality of brace-receiving slots, with each polymeric foamed material structure having at least one of the brace-receiving slots.
83. The method of claim 82 additionally comprising computer operating said plurality of cutters.
84. The method of claim 83 wherein said plurality of cutters are selected from the group consisting of hot wire cutters and laser cutters.
85. The method of claim 84 additionally comprising providing a plurality of brace members; and disposing the plurality of brace members in the plurality of brace-receiving slots of said polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each polymeric foamed material panel having at least one of the brace members.
86. The method of claim 84 wherein said at least one direction of travel comprises a first direction of travel, a second direction of travel immediately following said first direction of travel and being generally parallel to said generally perpendicular direction of travel, and a third direction of travel immediately following said second direction of travel.
87. The method of claim 86 wherein said first direction of travel is generally normal to said generally perpendicular direction of travel, and said second direction of travel is generally normal to said first direction of travel.
88. The method of claim 82 additionally comprising providing a plurality of brace members; and disposing the plurality of brace members in the plurality of brace-receiving slots of said polymeric foamed material structures to produce a plurality of polymeric foamed material panels, with each polymeric foamed material panel having at least one of the brace members.
89. A plurality of polymeric foamed material panels produced in accordance with the method of claim 88.
90. The method of claim 82 wherein said at least one direction of travel comprises a first direction of travel, a second direction of travel immediately following said first direction of travel and being generally parallel to said generally perpendicular direction of travel, and a third direction of travel immediately following said second direction of travel.
91. The method of claim 90 wherein said first direction of travel is generally normal to said generally perpendicular direction of travel, and said second direction of travel is generally normal to said first direction of travel.
92. A plurality of polymeric foamed material structures produced in accordance with the method of claim 90.
93. A plurality of polymeric foamed material structures produced in accordance with the method of claim 82.

Parent Case Info

This is a continuation patent application of patent application having Ser. No. 09/322,268, filed May 28, 1999 now abandoned. Patent application Ser. No. 09/322,268 was a continuation patent application of patent application having Ser. No. 09/003,747, filed Jan. 7, 1998, now U.S. Pat. No. 5,943,775. Patent application having Ser. No. 09/003,747 was a continuation-in-part of patent application having Ser. No. 08/556,265, filed Nov. 13, 1995, now U.S. Pat. No. 5,842,276. Benefit of all earlier filing dates is hereby claimed with respect to all common subject matter. This is a continuation-in-part patent application of copending patent application having Ser No. 08/556,265, filed on Nov. 13, 1995, and entitled “A SYNTHETIC PANEL AND METHOD.”

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Continuations (2)

	Number	Date	Country
Parent	09/322268	May 1999	US
Child	09/433543		US
Parent	09/003747	Jan 1998	US
Child	09/322268		US

Continuation in Parts (1)

	Number	Date	Country
Parent	08/556265	Nov 1995	US
Child	09/003747		US

Synthetic panel and method

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