Abstract:
This is an improved method of manufacturing building panels and wall sections so that the manufacture of these panels and walls will be more efficient and economical. The building panels and walls have an inner insulator core and two substantially parallel surface materials which are connected together by connector ties. The panels and walls are described in an earlier invention by the present inventor in U.S. Pat. No. 7,073,306 by Hagaman (2006). Included in the present invention are mechanisms and manufacturing machines which produce building panels in a continuous manner. This continuous manufacturing machinery is economical to build, economical to use, and energy efficient in its operation. Other improvements of the present invention are the manufacturing ability to readily make building panels of different thicknesses, widths and heights, quickly insert and attach connecting ties, and improve quality of the building panels.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is related to application Ser. No. 10/799,219, Filed Mar. 12, 2004 by the present inventor, now U.S. Pat. No. 7,073,306, granted Jul. 11, 2006. The present application claims the benefit of Provisional Patent Application Ser. No. 60/998,673, filed 2007 Oct. 11 by the present inventor. 
    
    
     FEDERALLY SPONSORED RESEARCH 
     Not Applicable 
     SEQUENCE LISTING OR PROGRAM 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to improvement of the manufacturing of building panels used in the construction of buildings and other static structures. 
     2. Background of the Invention 
     The present invention relates to mechanisms and methods of manufacturing building panels and wall sections. These panels and walls are described in an earlier invention by the present inventor in U.S. Pat. No. 7,073,306 by Hagaman (2006). The building panels and walls have an inner insulator core and two substantially parallel surface materials which are connected together by connector ties. There is a need for structurally sturdy, energy efficient buildings that use less resources and are affordable. The use of building panels reduces construction cost and highly insulated panels save energy and resources over the life of the structure. The present invention relates to improvements in the manufacturing of these building panels and walls, so that the manufacture of these panels and walls will be more efficient and economical. 
     Included in the present invention are mechanisms and manufacturing machines which produce building panels in a continuous manner. This continuous manufacturing machinery is economical to build, economical to use, and energy efficient in its operation. Other improvements of the present invention are the manufacturing ability to readily make building panels of different thicknesses, widths and heights, quickly insert and attach connecting ties, and improve quality of the building panels. 
     3. Objects and Advantages 
     I have invented methods of and apparatus for manufacturing building panels. My invention is applicable to a number of building methods and materials. These manufacturing methods produce high quality building panels and walls that offer high insulation, are non toxic, save material resources, and save energy. The present invention improvements in the manufacturing of these building panels and walls will make these building panels more affordable. 
     Accordingly, several objects and advantages of the invention are: 
     To provide a manufacturing method to produce an energy efficient building panel or wall. 
     To provide a manufacturing method that produces building panels in a continuous manner to reduce manufacturing expense. 
     To provide a manufacturing method that produces building panels in a energy efficient way. 
     To provide a manufacturing method to produce a low cost building panel or wall. 
     To provide a manufacturing method to produce a non-toxic building panel or wall. 
     To provide a manufacturing method that produces a building panel or wall efficiently and quickly. 
     Further objects and advantages will become apparent from consideration of the ensuing description and drawing. 
     SUMMARY OF THE INVENTION 
     The present invention relates to the manufacture of building panels and walls. 
    
    
     
       DRAWING 
       Figures 
       The accompanying drawings, which are incorporated into and from a part of the specification, illustrate several embodiments of the present invention and together with the description, serve to explain the principles of the invention. The drawing are only for the purpose of illustrating a few embodiments of the invention and are not to be construed as limiting the invention. 
       In the following detailed description, reference will be made to the attached drawings, in which: 
         FIG. 1  is a block diagram of a manufacturing method. 
         FIG. 2  is a cross sectional view of a manufacturing machine. 
         FIG. 3  is a cross sectional view of a panel press method. 
         FIG. 4  is a cross sectional view of a panel with mesh and perimeter frame. 
         FIG. 5  is a cross sectional view of a surface compression method. 
         FIGS. 6A and 6B  are cross sectional views of a panel edge compression method. 
         FIG. 6C  is a top view of a pressure plate. 
         FIG. 7  shows a two wire tie wrapping method. 
         FIG. 8  shows a one wire wrapping method. 
         FIG. 9  shows a single wire bent over attaching method. 
         FIG. 10  shows a slip-over tie end. 
         FIG. 11  is a front view of a mechanism that threads multiple wire ties through a panel and then attaches them. 
         FIG. 12  is a side view of a mechanism that threads multiple wire ties through a panel and then attaches them. 
         FIG. 13  is a cross sectional view which shows several details of the  FIGS. 11 and 12  above. 
         FIG. 14  shows a rotating tie wire channel. 
         FIGS. 15  A, B, C and D illustrate a lever crimping method. 
         FIGS. 16  A, B and C illustrate a lever and push bar wire crimping method. 
         FIGS. 17  A and B illustrate a wire bender and push bar crimping method. 
         FIG. 18  depicts a mobile version of the present invention. 
         FIG. 19  is a cross sectional view of a roller press method. 
         FIG. 20  is a cross sectional view of a roller press with rollers on top and bottom. 
     
    
    
     DRAWING 
     Reference Numerals 
     
         
           10  manufacturing method 
           11  inner core material 
           12  first facing material 
           13  second facing material 
           14  connecting tie 
           15  machine 
           16  building panels and wall sections 
           21  compressed inner core material 
           22  connecting tie mechanism 
           23  compressing roller belt 
           24  alignment traction nubs 
           25  panel surfacing synchronizing mechanism 
           26  conveyor belt 
           27  electrical chase 
           28  panel surfacing 
           31  series of rollers 
           36  roller table 
           38  panel thickness adjustment device 
           42  panel perimeter frame 
           52  pressure plate 
           54  base plate 
           62  pressure plate 
           64  forms 
           66  compression chamber 
           71  two wire tie 
           73  one wire tie 
           75  looped over mesh 
           76  mesh wire 
           100  clasping tie 
           110  frame support 
           111  main driver frame support and lower wire clamps 
           112  tie wire channel driver 
           113  tie wire channel base with upper wire clamps 
           114  piercing tie wire channel 
           115  frame lower crimping support and channel guides 
           116  lower crimping mechanism and wire cutter 
           117  upper crimping mechanism 
           118  panel passage 
           123  wire guide supports 
           124  wire spools 
           131  prong housing 
           132  support 
           133  wire 
           134  wire clamp prong 
           135  prong actuator 
           136  bolt 
           137  wire channel tip 
           138  support 
           139  support 
           146  tie wire channel rotating mechanism 
           144  rotating tie wire channel 
           148  tie wire channel cleaner 
           150  panel 
           151  mesh wire 
           152  lever 
           153  lever pivot 
           162  lever 
           163  mesh wire clasping arm 
           164  lever pivot 
           165  push bar 
           170  wire bender plate 
           180  farm field panel machine 
           182  agriculture materials 
           184  building panels. 
           190  base 
           191  roller 
           192  roller belt 
       
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The panel manufacturing methods and mechanisms of this invention relate to systems for producing building panels of various types that may satisfactorily be practiced to erect residential, commercial, or even industrial buildings. The description of the methods of fabrication and use of the present invention will enable one skilled in the art to adapt and adjust the disclosed methods and mechanisms to accomplish the fabrication of any number of mechanisms to produce building panels. The invention is widely applicable and some of the descriptions tend to be general because there are so many ways to make and use the invention. 
       FIG. 1  shows a block diagram of manufacturing method  10  which makes building panels and wall sections  16 . The building panels and wall sections consist of inner core material  11  sandwiched between and substantially parallel to first facing material  12  and a second facing material  13  connected together by connector ties  14 . Machine  15  connects inner core material  11 , first facing material  12 , and second facing material  13  together by placing connecting ties  14  through the inner core material  11  and attaching connecting ties  14  to first facing material  12  and second facing material  13 . Machine  15  also advances inner core material  11 . 
     Inner core material  11  can be any suitable material including fiber, straw, rice straw, agricultural biomass, wood chips and shaving, organic materials, paper, cardboard, bagasse, shredded plastic, and shredded paper. A facing material in the present invention can be any suitable material including wire mesh, plastic, jute, burlap, plywood, oriented strand board, and cement board. Connecting ties in the present invention can be any suitable material or design including wire, jute, strapping, hooks, cord, staples, and clasping ties. Metal welding can also be used to attach metal connecting ties to a metal mesh facing material. 
     A preferred embodiment of machine  15  compresses inner core material  11  when compression is desired.  FIGS. 2 ,  3 ,  5 ,  6 A, and  6 B show several preferred compression mechanisms. Another preferred embodiment of machine  15  has mechanisms which combine inner core material  11 , first facing material  12 , and second facing material  13  so that inner core material  11  is sandwiched between and substantially parallel to first facing material  12  and second facing material  13 .  FIGS. 11 ,  12 ,  13 ,  14 ,  15 ,  16 , and  17  show several preferred mechanisms to attach inner core material  11 , first facing material  12  and second facing material  13  together with connecting ties. 
       FIG. 2  shows a cross sectional view of a preferred building panel and wall section manufacturing machine which uses a compressing belt arranged in a slanting configuration so as to compress a straw panel.  FIG. 2  shows conveyor belt  26  and inner core material  11  on the center left, panel surfacing  28  above inner core material  11  and another panel surfacing  28  below inner core material  11 , electrical chase  27  is shown inserted into inner core material  11 , compressing roller belt  23  are above and below inner core material  11 , compressed inner core material  21  is on the right side bound by connector ties  14  and panel surfacing  28 , panel surfacing synchronizing mechanism  25 , and connecting tie machine  22 . 
     Above conveyor belt  26  is inner core material  11 . The arrow on the left shows the direction inner core material  11  moves on the conveyor belt  26 . Upper and lower panel surfacing  28  are unrolled and placed on the top and bottom of inner core material  11  as panel surfacing  28  and inner core material  11  advance through this machine. The inner core material  11  and panel surfacing  28  are compressed by the compressing roller belt  23 . Panel surfacing  28  can be any suitable surface material including mesh, screen, jute mesh. Compressing roller belt  28  may be used as a propelling mechanism though any suitable propelling mechanism can be used to move the inner core material  11  and panel surfacing  28  through the compressing roller belt  23 . Compressing roller belt  23  may have mechanisms like alignment traction nubs  24  which align panel surfacing  28  on the compressing roller belt  23 , other suitable alignment methods may be used. Panel surfacing synchronizing mechanism  25  is used to synchronize the upper and lower panel surfacing  28  by synchronizing compression roller belt  23 . Panel surfacing synchronizing mechanism  25  can also be designed to synchronize the panel surfacing  28  directly without engaging compression roller belt  23 . Panel surfacing  28  can also be placed on inner core material  11  after inner core material  11  has gone through compression (not illustrated) and aligned and synchronize also after compression takes place.  FIG. 2  shows a electrical chase  27  in inner core material  11 . Placing the electrical chase  27  in the inner core material  11  before compression makes it easier to get an electrical chase in the panel and reduces labor and costs associated with putting electrical chases in. 
     As the inner core material passes between compressing roller belt  23 , inner core material  11  is compressed and its thickness is reduced. The turning of the roller belt allows inner core material  11  to be compressed without inner core material  11  tending to be pushed backwards. Any suitable compressing roller belt can be used and rollers without belts can also be used to compress inner core material  11 . A single roller of suitable size can also be used to compress inner core material  11 . A height adjustment device that adjusts the distance between the upper and lower compressing mechanisms can be included to allow for various panel thicknesses. 
     Compressed inner core material  21  and panel surfacing  28  exit compressing roller belt  23  on the right hand side of  FIG. 2 . Then connecting tie machine  22  attaches the two panel surfacing  28  together with a connecting tie  14  which passes through compressed inner core material  21 . Connecting tie mechanism  22  can be any suitable connecting tie mechanism, and connecting tie  14  can be any suitable connecting tie. For instance the connecting tie mechanism illustrated in  FIGS. 11 and 12 , and the connecting tie illustrated in  FIGS. 7 ,  8 ,  9 , and  10 . 
       FIG. 3  is a cross sectional view of a preferred panel press method which uses a series of rollers  31  in a stepping configuration so as to compress inner core material  11 .  FIG. 3  shows a first facing material  12  above roller table  36 , second facing material  13  above inner core material  11 , step rollers  31 , connector tie  14 , connecting tie mechanism  22 , and panel thickness adjustment device  38 . The arrow on the left side shows the direction inner core material  11 , first facing material  12 , and second facing material  13  move relative to the rollers so as to be compressed. Any suitable propelling mechanism can be used to move the inner core material and facing materials along. Roller table  36  serves as a base that restricts movement, so that when inner core material  11  passes between step rollers  31  and roller table  36 , inner core material  11  is compressed and its thickness is reduced. When the inner core material and facing materials exit the roller press towards the right side of  FIG. 3 , connecting tie mechanism  22  binds them together. Connecting tie mechanism  22  can be any suitable connecting tie mechanism. For instance, if first facing material  12  and second facing material  13  are plywood, the connecting tie mechanism could connect the plywood facing and inner core material with ribbits, screws, staples, fasteners, and any other suitable connecting tie. If the facing materials are mesh, and/or a combination of a mesh and a plywood, other type fasteners and possibly a different connecting tie mechanism could be needed. 
     A single roller of suitable size can also be used. Panel thickness adjustment device  38  adjusts to allow for various panel thicknesses. Panel perimeter frames can be filled with inner core material and go through the panel press or these frames can be attached to the panels afterwards. Window and door bucks can also go through a roller press. Roller presses are versatile in this way. This allows custom panels to be manufactured more easily which reduces the custom panel cost and custom panels require less labor as compared to modifying panels on site, and so save construction time. 
       FIG. 4  is a cross sectional view of a building panel with panel perimeter frame  42 , connecting ties  14 , first facing material  12 , second facing material  13 , and compressed inner core material  21 . 
       FIG. 5  is a cross sectional view of a preferred surface compression method which illustrates inner core material  11  compressed between pressure plate  52  and base plate  54 . The movement of pressure plate  52  is shown by an arrow. Connecting ties  14  can attach inner core material  11 , first facing material  12 , and second facing material  13  together while still in the press, or connecting tie  14  can be attached as inner core material  11  and first facing material  12  and second facing material  13  are pushed out the side of the press (not illustrated). Another preferred way is to compress inner core material  11  and then as inner core material  11  is pushed out the side of the press, add first facing material  12 , second facing material  13 , and connect connecting tie  14  (also not illustrated). 
       FIGS. 6A and 6B  are cross sectional views of a preferred compression method.  FIG. 6A  includes pressure plate  62 , forms  64 , connecting tie mechanism  22 , first facing material  12 , second facing material  13 , compressed inner core material  21 , connecting tie  14 , and compression chamber  66 . In  FIG. 6B  inner core material  11  is loaded into the compression chamber area and pressure plate  62  moves in the direction of the arrow (located on the right) to compress the inner core material  11 . After pressure plate  62  compresses inner core material  11  between forms  64  and the previously compressed inner core material  21 , connecting tie mechanism  22  attaches connecting tie  14  to first facing material  12  and second facing material  13 . Pressure plate  62  is then retracted and the bound, compressed part of this panel is advanced to make room in compression chamber  66 . Then the process of loading inner core material  11 , compressing, tying, and advancing the materials is repeated until the panel is completed. First facing material  12  and second facing material  13  are shown coiled, but they can also be a substantially flat and/or rigid material like cement board and plywood. Connecting tie mechanism  22  can also mount on pressure plate  62 . 
       FIG. 6C  shows a top view of a preferred type of pressure plate  62 . On the left side of this preferred type of pressure plate  62  are a number of passages which allow easier passage of ties when binding compressed straw along the pressure plate. This reduces the amount of force required to insert a tie through the straw and can also assist guiding a tie through to a designated area on the opposing side. 
       FIGS. 7 ,  8 ,  9 , and  10  are several preferred connecting tie  14  attaching methods.  FIG. 7  depicts two wire tie wrapping  71  method, and shows two wire tie  71  attached on the intersection of mesh wire  76 .  FIG. 8  shows a one wire wrapping tie  73  method.  FIG. 9  shows a single wire looped over mesh  75  attaching method.  FIG. 10  is a tie end which can be slipped over a mesh wire and will then latch on to the mesh wire, and will not easily back out. The arrow on the right denotes the direction clasping tie  100  is moved so it slips over mesh wire  76 . Once inside clasping tie  100 , mesh wire  76  can not so easily go out the way it went in because of the slightly curved barb which will detain it there at least until clasping tie  100  is bent so far as the barb can no longer contain it. If force is applied in the opposite direction clasping tie  100  again has to be bent by that force so far as to no longer be able to contain mesh wire  76 . When a plaster is applied on a panel surface unhooking a tie end is much harder. 
       FIGS. 11 and 12  show a series of tie apparatus or mechanisms arranged in a row. Any suitable arrangement of tie mechanisms can be used, including: a single tie mechanism in which a panel is moved around so as to position the panel for the tie operation, a tie mechanism that is moved around a panel to position the tie operation, and an arrangement of tie mechanisms that can complete all the panel ties that an entire panel requires in one operation. Other configurations of this tying mechanism and its components can be built. For instance piercing tie wire channels  114  can insert the tie wire from the top. 
     The panel&#39;s materials, inner core material  11 , first facing material  12 , and second facing material  13 , pass through panel passage  118 . Panel passage  118  is drawn as a broken line. Tie wire channel drivers  112  drive piercing tie wire channels  114  through the panel materials in panel passage  118  by raising tie wire channel base with upper wire clamps  113 . Tie wire channel drivers  112  can be any suitable method and device such as pneumatic and hydraulic machinery. The upper wire clamps located on tie wire base with upper wire clamps  113  hold the wire in the wire channel as it goes up which also pulls wire from wire spools  124 . The upper wire clamps release on the tie wire channel driver  112  downstroke and the lower wire clamps located on main driver frame support and lower wire clamps  111  engage. The lower wire clamps hold the tie wire so that when the piercing tie wire channels  114  descend the tie wires remain in inner core material  11 . A portion of wire extending out the surfaces of the panel is left. This is used for attaching to the panel surface meshes. The wire clamps can be any suitable method, material, and design capable of detaining the tie wires. For instance, a pneumatic cylinder that actuates a metal push rod and/or cam locks. Piercing tie wire channels  114  can also be any suitable method, material, and design with which a tie can be inserted into a panel with. For instance, tubes, open channels, rotating tubes and rotating channels. 
     After the tie wires are deposited in the panel materials, wire cutters located on lower crimping mechanism and wire cutters  116  cut the wires and then the wire crimpers located on lower crimping mechanism and wire cutters  116  and upper crimping mechanism  117  attach the tie wire ends to the panel surface meshes. Wire crimpers can be any suitable method capable of attaching the tie wires. Wire cutters can be any suitable method for cutting the wires. 
       FIG. 13  is a cross sectional side view which shows several details of preferred mechanisms of  FIGS. 11 and 12 . In the center area of  FIG. 13  is tie wire channel with upper wire clamps  113 . Located on support  132  are piercing tie wire channel  114 , channel base/prong housing  131 , wire clamp prong  134 , and prong actuator  135 . Also shown is wire  133  which is guided through piercing tie wire channel  114 . Wire clamp prong  134  exerts pressure on wire  133  when prong actuator  135  pushes on it. This holds wire  133  in place during the upward motion of piercing tie wire channel  114  as it is driven through the panel materials. Towards the lower area of  FIG. 13  are main driver frame support and lower wire clamps  111  which clamps wire  133  during the piercing tie wire channels  114  downward stroke so that the upper portion of wire  133  will remain in the panel. Of course, the upper wire clamps must release wire  133  first. The upper portion of  FIG. 13  depicts frame lower crimping support and channel guides  115  which shows support  138  with a passage in it used as a guide for piercing tie wire channels  114 . Piercing tie wire channel  114  has a pointed wire channel tip  137  to facilitate easier piercing. After wire  133  has been set in a panel, the portions of wire  133  extending above and below the panel can be attached to a mesh. 
       FIG. 14  shows a rotating tie wire channel  144 , tie wire channel rotating mechanism  146 , and tie wire channel cleaner  148 . Tie wire channel rotating mechanism  146  rotates the rotating tie wire channel  144 . Rotating the tie wire channel facilitates the passage of the tie wire channel through the inner core material. Wire channel tip  137  can be any suitable type tip such as saw toothed and spiral tipped. Tie wire channels can get clogged.  FIG. 14  shows a tie wire channel cleaner  148 . Any suitable tie wire cleaning device can be used, such as compressed air devices. 
     A preferred crimping mechanism method is shown in  FIGS. 15  A, B, C, and D. These figures illustrate lever  152  folding wire  133  over mesh wire  151 , which is located on panel  150 .  FIG. 15A  shows the relative starting positions of panel  150 , mesh wire  151 , wire  133 , and lever  152 .  FIGS. 15  B, C, and D show lever  152  rotating on lever pivot  153  and folding wire  133  over mesh wire  151  so as to attach wire  133  to mesh wire  151 . The force required to rotate lever  152  and lever pivot  153  can be supplied by any suitable device and method. Lever  152  has a curved surface which stops inner core material from restricting lever  152  when exiting panel  150 . 
       FIGS. 16  A, B, and C illustrate a preferred wire crimping method which has a mesh wire clasping arm  163 , that holds mesh wire  151  in place when wire  133  is being folded over it by lever  162 . A mesh wire clasping arm can also be used with the crimping mechanism shown in  FIGS. 15  A, B, C and D.  FIGS. 16  A, B and C also illustrate push bar  165  being used to push a portion of wire  133  down into panel  150  so as to bend wire  133  around mesh wire  151 . The end of wire  133  can be left flared out to help stop wire  133  from loosening its grip around mesh wire  151 . This flared end restricts wire  133  movement even better when a plaster is applied. 
       FIG. 16A  shows elements of this tie wire crimping method at the beginning positions. Wire  133  extends above panel  150  with mesh wire  151  to its right. To the left of wire  133  is lever  162  which rotates on lever pivot  164  and has mesh wire clasping arm  163  attached to it.  FIG. 16B  shows lever  162  after it has rotated on lever pivot  164  to a substantially horizontal position and has bent the upper end of wire  133  over mesh wire  151 .  FIG. 16B  also shows mesh wire clasping arm  163  rotated so as to hold mesh wire  151  steady while wire  133  is being bent over mesh wire  151  by lever  162 .  FIG. 16C  shows push bar  165  extended through a opening in lever  162  and down into panel  150 , driving wire  133  down into panel  150  and around mesh wire  151 . Mesh wire clasping arm  163  has been removed from  FIG. 16C  for clarity. 
       FIGS. 17  A and B illustrate another preferred method for attaching tie wire to surface mesh.  FIG. 17A  shows the top portion of wire  133  bent over mesh wire  151  to a horizontal position by wire bender plate  170 . The arrow denotes the direction that wire bender plate  170  was moved to bend wire  133 .  FIG. 17B  shows the next step in attaching wire  133  to mesh wire  151 . Push bar  165  is driven down through an opening in wire bender plate  170  and into panel  150  so as to bend wire  133  around mesh wire  151 . 
       FIG. 18  depicts farm field panel machine  180  which is a mobile version of the present invention that picks up agriculture materials  182  from the field for use as an inner core material, and then produces building panels  184 . 
       FIG. 19  is a cross sectional view of a preferred panel press method which uses a series of rollers in a stepping configuration so as to compress a panel.  FIG. 19  shows a panel surfacing  28  above base  190  plate, another panel surfacing  28  partly coiled higher up, inner core material  11 , compressed inner core material  21 , rollers  191 , roller belt  192 , connecting tie  14 , and a tie mechanism denoted by a rectangle labeled connecting tie mechanism  22 . The arrow on the left side shows the direction the inner core material  11  and panel surfacing  28  move relative to the rollers so as to be compressed. Panel surfacing  28  can be any suitable surface material including mesh and plywood. Any suitable propelling mechanism can be used to move the inner core material and meshes through the rollers. As the inner core material passes between the roller and base plate the inner core material thickness is reduced. The turning of the rollers and roller belt allow the inner core material to be compressed without the inner core material tending to be pushed backwards. Roller belt  192  isn&#39;t necessary for the roller press to function and is shown here as an optional feature. The upper panel surfacing  28  is shown being deposited on inner core material  11  after inner core material  11  has gone through the roller press. The upper panel surfacing  28  can also be placed on inner core material  11  before inner core material  11  goes through the roller press. When the compressed inner core material  21  and panel surfacing  28  exit the roller press to the right side of  FIG. 19 , the tie mechanism binds them together. This tie mechanism can be any suitable tie mechanism. For instance the tie mechanism illustrated in  FIGS. 11 and 12  above. Though the arrow shows the inner core material being pushed through the roller press it can also be pulled through the roller press on top of lower panel surfacing  28  or between a lower and upper panel surfacing  28 . A roller press like this can also be pushed or pulled over a stationary inner core material  11  to compress it. A single roller of suitable size can also be used. The roller press can be adjustable to allow for various panel thicknesses. 
       FIG. 20  is a preferred method similar to  FIG. 19  with the exception of a few changes.  FIG. 20  has rollers above and below inner core material  11  and panel surfaces  28  so as to compress inner core material  11  from top and bottom. Another difference is the panel surfacing  28  is shown on inner core material  11  before going through rollers  191 , though panel surfacing  28  can also be deposited on inner core material  11  after inner core material  11  goes through roller  191 . No roller belts are shown in  FIG. 20  though they can be used if desired. Single rollers on top and bottom can also be used. 
     CONCLUSIONS, RAMIFICATIONS AND SCOPE OF THE INVENTION 
     It should be apparent to the reader that the present invention reduces manufacturing time which reduces costs. 
     The current invention helps make energy efficient housing affordable. 
     One of the characteristics of the present invention is its flexibility. It can accommodate various materials, shapes, sizes, and designs, and so the present invention&#39;s ramifications are widespread in scope. 
     The above description contains many specificities. These should not be construed as limitations on the scope of the invention but rather as exemplifications of one preferred embodiment thereof. Many other variations are possible, for instance: 
     Materials can be substituted for all elements of mechanisms and panels to suit. 
     Manufacturing methods can be designed to modify the panel structural characteristics such as diagonal ties. 
     Mechanisms to build curved panels can be built. 
     Tie mechanisms can be transportable and used on a construction site. 
     Operations and techniques in this method can be mechanized to any degree, limited only by the ability and skill one has to design and build such machines. It is expected with time and incentive this invention will be further automated. 
     Thus the scope of the present invention should be determined by the appended claims and their legal equivalents, rather then by the examples given.