Synthetic panel and method

A method for producing a polymeric foamed material panel including the steps of providing a polymeric foamed material; and cutting (e.g. hot wire cutting) the polymeric foamed material until reaching a preconfiguration cut point. The method further includes cutting subsequently from the preconfiguration cut point a brace-receiving configuration in the polymeric foamed material; and sliding a brace member into the brace-receiving configuration to produce a polymeric foamed material panel.

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 pre-fabricated 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 desire 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 do 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 having a defined planer surface 
and a pair of opposed ends; 
(b) cutting the polymeric foamed material of step (a) in a generally 
perpendicular direction from the defined planer surface until reaching a 
preconfiguration cut point; 
(c) cutting subsequently from the preconfiguration cut point a 
brace-receiving configuration in the polymeric foamed material such that 
the brace-receiving configuration terminates in the opposed ends; 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.degree. F. to 580.degree. 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, a first defined planer surface, and a pair of opposed first ends; 
(b) cutting the first polymeric foamed material in a generally 
perpendicular direction from the first defined planar surface until 
reaching a first preconfiguration cut point and cutting subsequently from 
the first preconfiguration cut point a first brace-receiving-configured 
slot in the first polymeric foamed material such that the first brace 
receiving configured slot terminates in the opposed first ends; 
(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, a second defined planar surface, and a pair of opposed second ends; 
(f) cutting the second polymeric foamed material in a generally 
perpendicular direction from the second defined planar surface 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 such that the second 
brace-receiving-configured slot terminates in the opposed second ends; 
(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 comprises 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 material 
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.degree. 
F. to 580.degree. 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 provides a method for producing a polymeric foamed 
material panel comprising the steps of: 
(a) providing a polymeric foamed material with a plan side surface in a 
generally stationary position, said polymeric foamed material having a 
defined planar surface and a pair of opposed ends; 
(b) cutting the generally stationary polymeric foamed material of step (a) 
in a generally perpendicular direction from the defined planar surface 
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 such that the brace-receiving configuration terminates in the 
opposed ends; and 
(d) sliding a brace member into the brace-receiving configuration to 
produce a polymeric foamed material panel. 
The present invention further 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 provides a method for producing a 
polymeric foamed material panel comprising the steps of: 
(a) providing a polymeric foamed material with a defined planar side 
surface and a pair of opposed ends; 
(b) cutting with a cutter in a generally perpendicular direction from the 
defined planar side surface a path in the polymeric foamed material of 
step (a) such that the path terminates in the opposed ends; 
(c) retracing the path of step (b) with the cutter to produce a 
brace-receiving configuration in the polymeric foamed material such that 
the brace-receiving configuration terminates in the opposed ends; and 
(d) sliding a brace member into the brace-receiving configuration to 
produce a polymeric foamed material panel. 
The present invention yet also further provides a method for producing a 
polymeric foamed material panel comprising the steps of: 
(a) providing a polymeric foamed material having a defined planar side 
surface and a pair of opposed ends; 
(b) contacting the defined planar side surface with a cutter; 
(c) cutting with the cutter polymeric foamed material in a generally 
perpendicular direction from the defined planar surface thereof until 
reaching a preconfiguration cut point within the polymeric foamed 
material; 
(d) cutting with the cutter from the cutting preconfiguration cut point of 
step (c) a slot in the polymeric foamed material of step (c) such that the 
slot terminates in the opposed ends; 
(e) cleaning the slot of step (d) with the cutter to produce a 
brace-receiving configuration in the polymeric foamed material such that 
the brace-receiving configuration terminates in the opposed ends; and 
(f) sliding a brace member into the brace-receiving configuration to 
produce a polymeric foamed material panel. 
The present invention also further accomplishes its desired objects by 
providing a polymeric foamed material panel comprising a panel consisting 
of a polymeric foamed material; a brace-receiving-configured slot disposed 
in the polymeric foamed material of the panel and a brace member disposed 
in the brace-receiving-configured slot in the polymeric foamed material of 
the panel. The brace-receiving-configured slot 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. 
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 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 this novel method and polymeric foamed material 
panel, a preferred embodiment being shown with reference to the 
accompanying drawings, by way of example only, wherein:

DETAILED DESCRIPTION OF THE INVENTION 
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 brace 
members 14 disposed in the polymeric foamed material 12. The polymeric 
foamed material 12 has a pair of opposed ends 12f and 12g (see FIGS. 1, 6, 
9 and 10). Each of the brace members 14 pass into a slot, generally 
illustrated as 30 (see FIGS. 8 and 14), which was preferably preformed or 
precut. As best shown in FIG. 6, 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 steel 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 slides 
14a, 14b, 14c, 14d and 14e which are all essentially surrounded by the 
polymeric foamed material 14. 
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 polymeric opening 17 (see FIGS. 10 and 11) in the polymeric 
foamed material 12. The conduit(s) 16 may be employed for any suitable 
use; for example, a utility receptor (e.g. electrical wires), water, gas, 
etc. The polymeric opening 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 opening 17 and/or slot 30 hardens and 
smooths the wall(s) to facilitate the sliding of the brace member(s) 14 
thereinto. As will be further explained below, the seared or cartherized 
wall 32 is preferably formed by hot wire cutting. 
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 opening(s) 18 has been 
aligned with any and all polymeric opening(s) 17, the conduit 16 may pass 
through the polymeric opening(s) 17 and through the 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 
circumference. 
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 
customed specified 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 super 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 
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 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 opening 17 or slot 30 
within the polymeric foamed material 12. Prior to commencing the formation 
of polymeric opening 17 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 opening 17 and/or slot 30. The polymeric opening 17 is more 
technically produced after a residual core 12A (see FIG. 11) is removed in 
any suitable manner or by any suitable means. 
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, polyurethene, 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: 
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 materials) 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 a 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. 
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 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 Star Mfg., Inc., a division of Star Foam, Inc. of Fort 
Worth, Tex. The computer 52 to operate the hot wire cutter assembly 50 may 
also be obtained from Star Mfg., Inc. The wire 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 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 58 would receive less than about five (5) 
amps. It is to be understood that the wire 58 may have any suitable 
diameter for practicing the present invention. 
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 the wire 58 of the hot wire 
cutter assembly 50. Commands are entered into the computer 52 and the wire 
58 is heated to a desired temperature (e.g. from about 230.degree. F. to 
about 580.degree. F., preferably from about 250.degree. F. to about 
350.degree. 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 12f and 12g of 
polymeric foamed material 12 (see FIGS. 19 and 10). As best shown in FIG. 
9, 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.degree. 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 12A is 
removed, the polymeric opening 17 is produced with slot 70 terminating in 
polymeric opening 17. As previously indicated, removal of the core 
material 12A 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 12A to further smooth and harden the same to facilitate 
the removal of the core material 12A. 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 12A 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 12f and 12g 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. 
Thus, 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 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 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 a 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. 
Thus further, by the 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. 
Thus also further, by the practice of this invention there is also provided 
a polymeric foamed material panel 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 panes(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 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 both the structure 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 of the invention as set forth.