Patent ID: 7291234

Claim:
A process for manufacturing composite structural insulated panels comprising: sequentially depositing lower boards on a conveyor of a conveying system between a pair buttresses that extend away from the conveyor and transporting the lower boards via the conveying system through an application zone wherein a multi-barrel extruder system mixes and applies a catalyzed foam mixture to one face of each successive lower board, the catalyzed foam mixture expanding upon application on the lower boards; sequentially depositing upper boards on a pair of stationary support rails at a desired height above the conveyor, the buttresses positively driving the upper boards alone the pair of stationary support rails at a complementary position over the respective lower boards and expanding catalyzed foam mixture; continuing to transport the lower boards, expanding foam mixture, and upper boards via the conveying system through a curing apparatus such that structural insulated panels are formed having a foam core of a selected thickness that is adhered to upper and lower boards.