Systems including modular structural panels of agricultural waste material and methods thereof
The lack of environmentally friendly and assembleable building components in the prior art is solved by using modular structural panel systems made of recycled agricultural waste, achieving high load capacity, chemical and biological resistance, and stackable building components.
Patent Information
- Application Number
- CN202380053099.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-05-12
- Filing Date
- 2023-05-12
- Publication Date
- 2025-02-28
AI Technical Summary
The prior art lacks a panel system made of a strong, environmentally friendly material that can be easily assembled together to form a durable structure and delivery method with increased load capacity.
A modular structural panel system is employed, made of recycled agricultural waste products, which includes panels with narrowing recesses and connectors through which the panels can be easily connected and separated to form stackable pallets or building elements.
Chemical and bioresistent, remanufactureable and stackable building elements are achieved, with load-bearing capabilities similar to wooden pallets and simplifying the construction process of building elements.
Smart Images
Figure CN119546827A_ABST
Abstract
Description
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 341,109, filed May 12, 2022. The entire contents of U.S. Provisional Patent Application No. 63 / 341,109 are incorporated herein by reference for all purposes. Technical Field
[0003] Embodiments described herein relate to building elements made from recycled agricultural waste products. More particularly, embodiments provide a system of modular structural panels, and methods of assembling and manufacturing the system. Background Art
[0004] The following does not constitute an admission that anything discussed below is part of the prior art or part of the common general knowledge to a person skilled in the art.
[0005] Agricultural waste materials are readily available, easily accessible, natural, renewable, sustainable, and have good physical properties. For example, corn is the most widely grown crop in the world. Corn husks are the inedible leafy husks of corn that are generally stripped from the cob and discarded. Approximately 45 million tons of corn husks are discarded each year. Corn husks consist of many individual fibers. These fibers exhibit high strength, high elongation, moderate durability, and good flexibility.
[0006] Currently, the manufacture of pallets for structural or shipping purposes may involve the use of wood, paper, cardboard, plant fibers, straw, waste paper, resins, mineral components, and cellulose fibers. Further manufacturing processes can create building materials (such as boards, panels, columns, beams, siding, sheathing, trusses, blocks, and shingles) that can be formed into any desired shape or size.
[0007] However, the industry lacks a panel system made of strong, environmentally friendly materials that can be easily assembled together to form a durable structure with increased load capacity and transportation method. BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a better understanding of the described embodiments, and to show more clearly how they may be implemented, reference will now be made, by way of example, to the accompanying drawings, in which:
[0009] Figure 1 shows a top perspective view of an example modular structural panel according to an example embodiment;
[0010] Figure 2 Shows Figure 1 A top view of a modular structural panel;
[0011] Figure 3Shows Figure 1 A bottom-up perspective view of the modular structural panels;
[0012] Figure 4a Shows Figure 2 An enlarged view of section A;
[0013] Figure 4b Shows Figure 3 An enlarged view of section B;
[0014] Figure 5 shows a top perspective view of a modular structural panel according to another example embodiment;
[0015] Figures 6a to 6e showing a number of top views of an example system of modular structural panels according to an example embodiment;
[0016] Figure 7 A flow chart illustrating a method of assembling a system of modular structural panels according to an example embodiment;
[0017] Figure 8 A flow chart illustrating a method of assembling a system of modular structural panels according to another example embodiment;
[0018] Fig. 9 A flow chart illustrating a method of assembling a system of modular structural panels according to another example embodiment;
[0019] Fig.10 a front perspective view showing an example use of two or more modular structural panels according to an example embodiment;
[0020] Fig.11 shows a top view of an example modular structural panel according to another example embodiment;
[0021] Fig.12 shows a top view of an example modular structural panel according to another example embodiment; and
[0022] Fig.13 A front perspective view illustrating an example use of a system of modular structural panels according to at least one embodiment.
[0023] The drawings included herein are used to illustrate various examples of the articles, systems, and methods taught by this specification, and are not intended to limit the scope of the teachings in any way. For simplicity and clarity of explanation, the elements shown in the drawings are not necessarily drawn to scale. For clarity, the sizes of some of the elements may be exaggerated relative to other elements. It will be understood that, for simplicity and clarity of explanation, where appropriate, reference numerals may be repeated in the drawings to indicate corresponding or similar elements or steps, or repeated instances of similar features may be omitted. DETAILED DESCRIPTION
[0024] Various devices are described below to provide examples of one or more embodiments. Any embodiment described below does not limit any claim and any claim may cover devices that are different from the devices described below. The claims are not limited to devices, methods, or systems having all the features of any one device, method, or system described below or features common to multiple or all devices, methods, and systems described below.
[0025] The device, system or method described herein may not be an embodiment of any claim. Any embodiment disclosed herein that is not claimed in this document may be the subject of another protective instrument (e.g., a continuing patent application), and the applicant, inventor or owner does not intend to abandon, disclaim or dedicate any such embodiment to the public solely by its disclosure in this document.
[0026] Unless expressly stated otherwise, the terms "comprises," "includes," and variations thereof mean "including, but not limited to." Unless expressly stated otherwise, a listing of items does not imply that any or all of the items are mutually exclusive. Unless expressly stated otherwise, the terms "a," "an," and "the" mean "one or more."
[0027] As used herein and in the claims, two or more parts are referred to as being "coupled," "connected," "attached," "mounted," or "fastened," wherein the parts are directly or indirectly (i.e., through one or more intermediate parts) linked together or operated together whenever a link occurs. As used herein and in the claims, two or more parts are referred to as being "directly coupled," "directly connected," "directly attached," or "directly fastened," wherein the parts are connected to each other in physical contact. As used herein, two or more parts are referred to as being "rigidly coupled," "rigidly connected," "rigidly attached," or "rigidly fastened," wherein the parts are coupled so as to move as a unit while maintaining a constant orientation relative to each other. None of the terms "coupled," "connected," "attached," "mounted," and "fastened" distinguish the manner in which two or more parts are coupled together.
[0028] Some elements herein may be identified by a part number consisting of a base number followed by an alphabetic or subscript numeric suffix (e.g., 112a or 1121). Multiple elements herein may be identified by part numbers that share a common base number and have different suffixes (e.g., 1121, 1122, and 1123). In some cases, the base number without the suffix (e.g., 112) may be used to collectively or generically refer to elements having a common base number.
[0029] It should be noted that, as used herein, terms of degree, such as "substantially", "approximately", and "approximately", mean a reasonable amount of deviation of the modified term such that the end result will not be significantly changed. Such terms of degree may also be construed to include a deviation (such as 1%, 2%, 5% or 10%) of the modified term if such deviation does not negate the meaning of the term it modifies.
[0030] It should also be noted that, as used herein, the term "and / or" is intended to mean an inclusive "or." That is, "X and / or Y" is intended to mean, for example, X or Y or both X and Y. As a further example, "X, Y and / or Z" is intended to mean X or Y or Z or any combination of X, Y, and Z.
[0031] In addition, numerical ranges recited herein by endpoints include all numbers and fractions subsumed within this range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.90, 4, and 5). It should also be understood that all numbers and fractions thereof are considered to be modified by the term "about", which means the maximum amount of variation (such as 1%, 2%, 5%, or 10%) of the number involved if the end result is not significantly changed.
[0032] Overview
[0033] In some examples, similar reference numerals may be used in different figures to represent similar components. In some examples, similar features may be labeled in only one instance for simplicity and clarity of the drawings.
[0034] Wooden pallets are a common element associated with the shipping industry. They facilitate the stacking and movement of bulk cargo from manufacturers to consumers and various places in between. However, upon arrival at the final destination, wooden pallets are often discarded or incinerated. Despite some efforts to reuse discarded wooden pallets, there are many limitations. For example, older wooden pallets are treated with chemicals that are harmful to humans through contact or inhalation. Although newer pallets are generally untreated, they may still be contaminated during transportation by absorbing spilled harmful chemicals. Wood is also at risk of mold or insect infestation. Another limitation includes the variability in the size of wooden pallets, which are unstable and difficult to remove or connect without additional tools and materials. Each of the limitations described makes wooden pallets unsuitable or inferior for reuse (such as for the construction of building elements).
[0035] Therefore, an alternative to traditional wooden pallets is desired. Various embodiments described herein generally relate to systems of modular structural panels and methods of assembling and manufacturing the same. The modular structural panels and systems thereof can utilize agricultural waste products and attempt to overcome the problems of traditional wooden pallets. In particular, the modular structural panels and systems thereof can provide chemically and biologically resistant, reproducible and stackable pallets, have load-bearing capacities similar to wooden pallets, and modularity that helps simplify the construction of building elements.
[0036] Modular structural panels
[0037] Reference now Figure 1 , Figure 1 An example modular structural panel 100 is illustrated according to an example embodiment. The modular structural panel 100 includes a planar surface 110 defining a first plane. The planar surface 110 includes one or more tapered recesses 120a, 120b, 120c located proximate to an interior, edge, and / or corner of the planar surface 110. For simplicity and clarity of illustration, repeated instances of each tapered recess type are not labeled.
[0038] Still reference Figure 1, connectors 130a, 130b connecting adjacent modular structural panels 100 are also shown. The shape and size of the connectors 130a, 130b are designed so that the connectors are received in adjacent, aligned narrowed recesses of adjacent modular structural panels 100. For example, the connector 130a can connect two modular structural panels 100. The two modular structural panels 100 can be aligned so that the narrowed recesses 120b of each modular structural panel 100 are side by side. Then, the connector 130a can be placed to connect each narrowed recess 120b of each modular structural panel 100. In another example, the connector 130a can connect two, three or four modular structural panels 100 at the aligned narrowed recesses 120c. In such examples, a plurality of modular structural panels 100 can be aligned so that the narrowed recesses 120c of each modular structural panel 100 are side by side. Then, the connector 130a can be connected to each modular structural panel 100 through the narrowed recess 120c. Other shapes of the connector 130a are possible. For example, the connector 130a can be substantially "L" shaped for connecting three modular structural panels at aligned narrowed recesses 120c. The connector 130a can, for example, be substantially shaped as a right angle. In another example, the connector 130b can connect two modular structural panels at aligned narrowed recesses 120c. When inserted into the narrowed recesses 120b, 120c, the connectors 130a, 130b can be substantially coplanar with the flat surface 110 so that the surface of the modular structural panel 100 is substantially flat. For example, the shape of the narrowed recesses 120a, 120b and the corresponding connectors 130a, 130b can be shapes other than those depicted (such as substantially triangular or circular). With respect to Figure 4a to Figure 4b and Figures 6a to 6e The connector is further described.
[0039] Still reference Figure 1 , in which cover plates 140a, 140b, 140c are shown, and the shapes and sizes of the cover plates 140a, 140b, 140c are correspondingly designed so that the cover plates are received in each narrowed recess 120a-c and cover each narrowed recess 120a-c. For example, when the recesses located near the edges or corners of the flat surface 110 are not used to connect the modular structural panel 100 to another modular structural panel 100, these recesses can be enclosed by correspondingly inserting the cover plates 140b and 140c. The recesses located near the interior of the flat surface 110 can be similarly enclosed by the cover plate 140a. In the illustrated embodiment, the cover plates 140a and 140b are substantially similar to the connectors 130a and 130b, respectively. For simplicity, these are not shown in FIG. Figure 1When inserted into the narrowed recesses 120a-c, the cover panels 130a-c can be substantially coplanar with the flat surface 110, making the surface of the modular structural panel 100 substantially flat. As disclosed herein, the shapes of the narrowed recesses 120a-c and corresponding cover panels 140a-c can be other shapes besides the shapes depicted. Figure 4a to Figure 4b and Figures 6a to 6e Cover plates 140a-c are further shown and described.
[0040] For example, briefly refer to Fig.11 and Fig.12 , wherein top views of example embodiments of modular structural panels 400 and 500 are shown, respectively. For simplicity and clarity of illustration, repeated instances of each narrowed recess type are not labeled. Within the planar surface 410 of the modular structural panel 400 are narrowed recesses 420a, 420b, 420c, wherein the recesses positioned near the interior are substantially square and the recesses positioned near the edges or corners are substantially triangular. Within the planar surface 510 of the modular structural panel 500 are narrowed recesses 520a, 520b, 520c. In this embodiment, the orientation of the narrowed recesses 520a-c is substantially similar to Fig.11 . However, the recesses close to the interior positioning and edge positioning are divided into four sub-recesses and two sub-recesses respectively. Therefore, in this embodiment, all connectors and cover plates can be the same shape and size. Alternative shapes and sizes can be used, for example, to improve the retention strength of the connection and / or to produce a specific pattern on the flat surface of the modular structural panel.
[0041] In some embodiments, alternative systems of connectors 130a, 130b may be used to connect two structural panels 100. For example, the structural panels 100 may be connected by fasteners, nails, bolts, or any other connection mechanism. In an example embodiment, the structural panels 100 may each have a recessed portion located along one side of the structural panel 100, and a protrusion located along an opposite side of the structural panel 100. In the described embodiment, the protrusion of the first structural panel 100 may be received by the recessed portion of the second structural panel 100 to connect the structural panels 100 together. The protrusions and / or recesses may be included in the structural panels 100 to facilitate connecting the structural panels 100 in any desired manner, such as along adjacent walls or along a single wall.
[0042] Reference now Figure 2 , which shows Figure 11 is a top view of a modular structural panel 100. As shown, the flat surface 110 includes narrowed recesses 120a-c. For simplicity and clarity of illustration, repeated instances of each narrowed recess type are not labeled. The interior of the narrowed recess will be discussed in more detail in subsequent paragraphs. Figure 4a discuss Figure 2 Section A of .
[0043] Now refer to Figure 3 , Figure 3 Shows Figure 1 1 is a bottom view of a modular structural panel 100. A plurality of support members 150a, 150b, 150c are shown that can extend relative to the planar surface 110 for supporting the modular structural panel 100. Each support member 150a-c extends to a second plane that is substantially parallel to the planar surface 110, such that the length of each support member is substantially the same. For simplicity and clarity of illustration, repeated instances of each support member type are not labeled. Figure 4b discuss Figure 3 Section B of the .
[0044] like Figure 3 As shown, each narrowed recess 120a-c can correspond to a support member 150a-c accordingly. For example, each narrowed recess 120a positioned near the interior of the flat surface 110 can extend through the flat surface 110 and enter the corresponding support member 150a to form a cavity therein. Similarly, each narrowed recess 120b positioned near the edge of the flat surface 110 can extend through the flat surface 110 and enter the corresponding support member 150b to form a cavity therein. Each narrowed recess 120c positioned near the corner of the flat surface 110 can extend through the flat surface 110 and enter the corresponding support member 150c to form a cavity therein. For example, in another embodiment, a plurality of hollow support members can be removably connected to the flat surface below each narrowed recess.
[0045] Each modular structural panel may also include at least one first group of beams 172a, 172b, 172c, 172d extending opposite to the flat surface 110 between at least two adjacent support members for structural reinforcement of the flat surface. For simplicity and clarity of illustration, repeated instances of each feature are not labeled. Each beam in the first group of beams 172a-d may carry a portion of a load (such as a compressive load or a tensile load) received by the flat surface 110 in a direction perpendicular to the flat surface 110, or a load (such as a shear load) along a first plane of the flat surface. For example, each beam in the first group of beams 172a-d may extend opposite to the flat surface 110 to a position between the first plane and the second plane so that the forks of a forklift may pass under them to lift the modular structural panel 100.
[0046] Still reference Figure 3 , each modular structural panel may further include a second set of beams 170a, 170b extending opposite the planar surface 110, the second set of beams 170a, 170b being substantially perpendicular to the first set of beams. In at least one embodiment, the second set of beams 170a, 170b and the first set of beams 172a-d may intersect. In at least one embodiment, the planar surface 110, the support members 150a-c, each beam of the first set of beams 172a-d, and the second set of beams 170a, 170b may be integrally formed. For simplicity and clarity of illustration, repeated instances of each feature are not labeled.
[0047] In the illustrated embodiment, the first set of beams includes one or two outer beams 172a, 172d and one or two inner beams 172b, 172c, depending on whether they extend near the edge or inside the planar surface 110. Each beam in the first set of beams 172a-d can carry a portion of a load received by the planar surface 110 in a direction perpendicular to the planar surface 110, such as a compressive load or a tensile load, or a load along a first plane of the planar surface, such as a shear load. For example, each beam in the first set of beams 172a-d can extend to a position between the first plane and the second plane opposite the planar surface 110 so that the forks of a forklift can pass under them to lift the modular structural panel 100.
[0048] exist Figure 3In the illustrated embodiment, the beams 172b and 172c in the first group of beams define a channel 180 passing through each support member 150a, 150b. The beams 172b and 172c can intersect the support member 150a and protrude into the narrowed recess 120b. In the absence of one of the beams 172b and 172c, such as along the edge of the modular structural panel 100, a channel can be formed by connecting to an adjacent modular structural panel. The shape and size of each channel 180 can be designed so that each channel receives one of a plurality of structural building members. For example, the shape and size of the channel can be designed so that the channel receives 2×4, such as for building a wall. In another example, the shape and size of the channel can be designed so that the channel receives 2×8, such as for use as a floor joist. Other channel sizes are also possible.
[0049] In the illustrated embodiment, the beam 170a in the second group of beams may intersect the support member 150a and the beams 172b and 172c within the narrowed recess 120a. The beam 170b in the second group of beams may not intersect any of the support members 150a-c. In at least one embodiment, the beam 170a does not pass through the channel 180, thereby providing a clear path for the channel 180 to receive structural building members. In another embodiment, the beam 170a may span through the support member 150a and the channel 180. The beam 170a may define at least one slot within the narrowed recess 120a-c where the support members 150a-c and the beams 172b and 172c intersect. In another example embodiment, the beam 170a may be positioned to extend between the outer edges of the support members 150a-c.
[0050] Other extension distances are also possible. For example, each of the first set of stringers 172a-d can extend to the second plane so that the forks of a forklift can only be received below each of the second set of stringers 170a, 170b. In another example, each of the second set of stringers 170a, 170b can extend to the second plane so that the forks of a forklift can only be received below the second set of stringers 172a-d. In yet another example, all of the stringers can extend to the second plane, and each of the first set of stringers 172a-d and / or the stringers of the second set of stringers 170a, 170b can have a recessed portion defining a slot through which the forks of a forklift can be received.
[0051] Reference now Figure 4a and Figure 4b , which shows Figure 2 and 3 An enlarged view of section A and section B. Figure 4a, showing a top view of an inner narrowing recess 120a, an edge narrowing recess 120b, and a corner narrowing recess 120c of an example embodiment of a modular structural panel. Figure 4b , showing a bottom perspective view of connector 130a / cover 140a, connector 130b / cover 140b, and cover 140c. To clarify the relationship between connectors 130a, 130b, and / or covers 140a-c having narrowed recesses 120a-c, reference will be made to Figure 4a and Figure 4b For simplicity and clarity of illustration, repeated instances of each feature have not been labeled, and reference will be made to a single instance intended to represent each repeated instance of each feature.
[0052] The narrowed recesses 120a-c can include cavities 160a, 160b, 160c. Each narrowed recess 120a-c can extend through the flat surface 110 and into the corresponding support member 150a to form a cavity 160a-c therein. In at least one embodiment, each cavity 160a-c can have at least one slot 162a, 162b, 162c. As shown, the slots 162a-c can be formed between the inner edges of the cavities 160a-c and the beams 170a.
[0053] Each connector 130a, 130b can have at least one protrusion 132a, 132b, and the shape and size of the at least one protrusion 132a, 132b are designed so that the at least one protrusion is engaged in the narrowed recess 120a-c. The protrusions 132a, 132b can extend from the surface opposite to the flat surface 110. The protrusions 132a, 132b can be rectangular, square, circular, oval, triangular or any other applicable shape. The shape and size of each slot 162a-c can be designed so that each slot receives at least one protrusion 132a, 132b of each connector with an interference fit to fix two or more modular structural panels together. For example, the protrusion 132a of the connector 130a can slidably engage the slot 162b of the cavity 160b, or the slot 162c of the cavity 160c. Similar protrusions can be received in similar slots. This can be done to fasten two adjacent modular structural panels together along their edges, or to fasten two, three or four modular structural panels together at their corners, respectively. Figures 6a to 6e Further disclosed is securing a plurality of structural panels together. Similarly, the protrusion 132b of the connector 130b can slidably engage the slot 162c of the cavity 160c to secure two adjacent modular structural panels together at their corners. In at least one embodiment, each connector 130a, 130b can have at least a first protrusion 132a, 132b and a second protrusion 134a, 134b.
[0054] Each cover plate 140a, 140b, 140c may similarly have at least one protrusion 142a, 142b, 142c, the shape and size of the at least one protrusion 142a, 142b, 142c being designed so that the at least one protrusion engages each narrowed recess 120a-c to secure the cover plate in place. The protrusions 142a-c may be rectangular, square, circular, oval, triangular, or any other suitable shape. In at least one embodiment, the shape and size of the at least one slot 162a-c of each cavity 160a-c may be further designed so that the slot interference fits to receive one protrusion 142a-c of each cover plate to secure the cover plate in place. For example, the protrusion 142a of the cover plate 140a may slidably engage the slot 162a of the cavity 160a to enclose the narrowed recess 120a. Similarly, the protrusion 142b of the cover plate 140b can slidably engage the slot 162b of the cavity 160b to enclose the narrowed recess 120b. The protrusion 142c of the cover plate 140c can slidably engage the slot 162c of the cavity 160c to enclose the narrowed recess 120c. Similar protrusions can be received in similar slots.
[0055] Still refer to Figure 4a and Figure 4b In another embodiment, each connector 130a, 130b may have at least two protrusions 132a and 134a, 132b and 134b positioned proximate to each other. The shape and size of the at least two protrusions may be designed so that the at least two protrusions engage each adjacent narrowed recess 120a-c to secure two or more modular structural panels together. The protrusions 132a, 134a, 132b, 134b may be rectangular, square, circular, oval, triangular, or any other suitable shape. Figure 4a to Figure 4b In the illustrated embodiment, for example, two protrusions 132a and 134a can be placed within the cavity 160a of the narrowed recess 120a. The first protrusion 132a can slidably engage the slot 162a of the cavity 160a, while the second protrusion 134a can be located on the inner surface of the beam 170a, so that each protrusion 132a, 134a straddles the beam 170a, thereby holding the connector 130a in place on the narrowed recess 120a.
[0056] In another embodiment, each cavity 160a-c can have at least one track extending through the cavity, each track being shaped and sized so that each track is received between two protrusions 132a, 134b of each connector 130a, 130b with an interference fit to secure two or more modular structural panels together. In such an embodiment, the stringers 170a can extend between the support members 150a-c and do not intersect the narrowed recesses 120a-c to allow at least one track to extend through the cavities 160a-c.
[0057] Each cover plate 140a-c may similarly have at least two protrusions 142a-c, 144a, 144b, 144c shaped and sized so that the at least two protrusions engage each narrowed recess 120a-c to secure the cover plate in place. The protrusions 142a, 144a, 142b, 144b may be rectangular, square, circular, oval, triangular, or any other suitable shape. Figure 4a to Figure 4b In the illustrated embodiment, for example, two protrusions 142a and 144a can be placed within the cavity 160a of the narrowed recess 120a. The first protrusion 142a can slidably engage the slot 162a of the cavity 160a, while the second protrusion 144a can be located on the inner surface of the beam 170a, so that each protrusion 142a, 144a straddles the beam 170a, thereby holding the connector 130a in place on the narrowed recess 120a.
[0058] In another embodiment, each cavity 160a-c can have at least one track extending through the cavity, each track being shaped and sized so that each track is received between two protrusions 142a, 144b of each cover plate 140a, 140b with an interference fit to secure two or more modular structural panels together. In such an embodiment, the beam 170a can extend between the support members 150a-c and not intersect the narrowed recesses 120a-c to allow at least one track to extend through the cavity 160a-c.
[0059] Reference now Figure 5 , which shows various narrowed recesses enclosed therein Figure 11. An exemplary embodiment of a modular structural panel 100 of the present invention. For example, a narrowed recess located near the interior of the planar surface 110 has been enclosed by the cover 140a. A narrowed recess 120b located near the edge of the planar surface 110 may be enclosed by the cover 140b or the connector 130a, and a narrowed recess 120c located near the corner of the planar surface 110 may be enclosed by the connector 130b or 130a. For simplicity and clarity of illustration, repeated instances of each feature are not labeled.
[0060] Each modular structural panel can be used as one or more of a pallet, a floor component, or a wall component. For example, Fig.13 An example embodiment is shown in which a plurality of modular structural panels are delivered as pallets via forklift and then connected and installed as both floors (system 800 of modular structural panels) and walls (system 900 of modular structural panels).
[0061] Method of assembling a system of modular structural panels
[0062] Now refer to Figure 7 , Figure 7 A flow chart of an exemplary method 1000 for assembling a modular structural panel system is shown. To assist in describing the method 1000, reference will be made to Figures 6a to 6e .exist Figures 6a to 6e In the modular structure, each panel is basically similar to Figures 1 to 5 , wherein similar features are labeled in increments of 100. For simplicity and clarity of illustration, repeated instances of each feature are not labeled.
[0063] At step 1010, if Figure 6a As shown in FIG. 1 , a first modular structural panel 100 is positioned adjacent to a second modular structural panel 200 .
[0064] At step 1020, if Figure 6b As shown, the first edge 102 of the first modular structural panel 100 is positioned to abut against the first edge 202 of the second modular structural panel 200 .
[0065] At step 1030, if Figure 6b As shown, each support member corresponding to the narrowed recesses 120b and 120c proximate the first edge 102 of the first modular structural panel 100 is substantially aligned with each support member corresponding to the narrowed recesses 220b and 220c proximate the first edge 202 of the second modular structural panel 200 .
[0066] At step 1040, if Figure 6cAs shown, the first modular structural panel 100 is removably connected to the second modular structural panel 200 along the butting edges 102, 202 by inserting at least one connector 130a-b into each of the plurality of adjacent narrowed recesses 120b-c, 220b-c. Figure 6b to Figure 6c In the illustrated embodiment, the connector 130a can be inserted into the adjacent narrowed recesses 120b and 220b. The adjacent narrowed recesses 120c and 220c can be similarly connected by the connector 130a or 130b, depending on whether they are connected to another modular structural panel. For example, in one embodiment, only the first modular structural panel 100 and the second modular structural panel 200 are connected, and the connector 130b can be placed in the adjacent narrowed recesses 120c and 220c. In another embodiment, for example, where more than two modular structural panels can be connected, the connector 130a can be placed in the adjacent narrowed recesses 120c and 220c. In the embodiment, the connector 130a can be used to connect two other modular structural panels.
[0067] At optional step 1050, if Figure 6c to Figure 6d As shown, a narrowed recess 120a, 120b, 120c, 220a, 220b, 220c, independent of any adjacent narrowed recess, may be covered by inserting at least one cover plate 140a, 140b. A narrowed recess 120b, 120c, 220b, 220c adjacent to an adjacent narrowed recess may be covered by at least one connector 130a, 130b, 130c. Figure 6d The modular structural panels 100 and 200 are shown connected along their respective first edges 102, 104, wherein all the narrowed recesses are closed. The flat surface 110 and the flat surface 210 and each cover plate and connector can be substantially coplanar with the first plane, so that the flat surfaces 110, 210 are substantially flat. In another embodiment, the additional modular structural panel can be connected to the second edge 104 or the fourth edge 108 of the modular structural panel 100, or any of the second edge 204, the third edge 206 or the fourth edge 208 of the modular structural panel 200. The third edge 106 of the modular structural panel 100 is shown as being enclosed by the cover plate, and therefore cannot be connected to the additional modular structural panel. For example, this can be done for various reasons such as along the finished edge. Depending on the number and position of the additional modular structural panels to be connected, other connector and cover plate configurations are also possible. For example, this may depend on the intended use of the system of modular structural panels. In the embodiment shown, the modular structural panel is substantially square. For example, in some embodiments, other panel shapes such as triangles or hexagons are also possible.
[0068] exist Figure 6e In optional step 1060 shown in FIG. 1 , steps 1010 to 1050 may be repeated for each additional modular structural panel to be added to the system of modular structural panels. Figures 6a to 6d 1010 to 1050, the system now comprising three modular structural panels 100, 200, 300. The planar surface 110, 210, 310 and each cover and connector may be substantially coplanar with the first plane, such that the planar surface 110, 210, 310 is substantially planar.
[0069] Reference now Figure 8 , Figure 8 Another example method 1100 of a system for assembling modular structural panels is shown. Steps of method 1100 that correspond to steps of method 1000 have been similarly numbered. Steps 1010, 1020, and 1030 of method 1000 are substantially similar to steps 1110, 1120, and 1130 of method 1100. To aid in describing method 1100, reference will be made to steps 1110, 1120, and 1130 of method 1100. Figure 4a to Figure 4b And refer again Figures 6a to 6e .
[0070] At step 1140, if Figure 4a to Figure 4b and Figure 6b to Figure 6c As shown, the first modular structural panel 100 can be removably connected to the second modular structural panel 200 along the butt edges 102, 202. At least one connector 130a, 130b is inserted into each adjacent narrowed recess, wherein at least one protrusion 132a, 132b is slidably engaged in at least one slot 162b, 162c in the cavity 160b, 160c of the first modular structural panel 100 and the second modular structural panel 200. Each aligned support member corresponds to a narrowed recess 120b, 120c along the butt edges 102, 202. Adjacent recesses 120b, 220b and 120c, 220c can be connected using any of the connectors 130a, 130b as described herein.
[0071] In optional step 1150, if Figure 4a to Figure 4b and Figure 6c to Figure 6dAs shown, the narrowed recesses 120a-c, 220a-c, which are independent of any adjacent narrowed recesses, can be covered by inserting at least one cover plate 140a-c. At least one protrusion 142a-c of at least one cover plate 140a-c can be slidably engaged in at least one slot 162a-c in the cavity 160a-c of each support member. The support members along the butting edges 102, 202 can be covered without the cover plates 140a-c. The narrowed recesses 120b, 120c, 220b, 220c adjacent to adjacent narrowed recesses can be covered by at least one connector 130a, 130b.
[0072] At optional step 1160, steps 1110 to 1150 may be repeated for each additional modular structural panel to be added to the system of modular structural panels.
[0073] Reference now Fig. 9 , Fig. 9 Another example method 1200 of a system for assembling modular structural panels is shown. Steps of method 1200 that correspond to steps of method 1000 have been similarly numbered. Steps 1010, 1020, and 1030 of method 1000 are substantially similar to steps 1210, 1220, and 1230 of method 1200. To aid in describing method 1200, reference will again be made to steps 1010, 1020, and 1030 of method 1000. Figure 4a to Figure 4b and Figures 6a to 6e .
[0074] At step 1240, if Figure 4a to Figure 4b and Figure 6b to Figure 6c As shown, the first modular structural panel 100 can be removably connected to the second modular structural panel 200 along the butt edges 102, 202. At least one connector 130a, 130b can be inserted into each adjacent narrowed recess, wherein at least one track in the cavity 160b, 160c of each aligned support member corresponding to the narrowed recess 120b, 120c along the butt edges 102, 202 can be slidably engaged between at least two protrusions 134a, 134b. Adjacent recesses 120b, 220b and 120c, 220c can be connected using any of the connectors 130a, 130b as described herein.
[0075] In optional step 1250, if Figure 4a to Figure 4b and Figure 6c to Figure 6dAs shown, the narrowed recesses 120a-c, 220a-c, independent of any adjacent narrowed recesses, may be covered by inserting at least one cover plate 140a-c. In addition to the support members along the butting edges 102, 202, at least one track in the cavity 160a-c of each support member may be slidably engaged between at least two connector protrusions 144a-c. The narrowed recesses 120b, 120c, 220b, 220c adjacent to adjacent narrowed recesses may be covered by at least one connector 130a-c.
[0076] At optional step 1260, steps 1210 to 1250 may be repeated for each additional modular structural panel to be added to the system of modular structural panels.
[0077] In at least one embodiment of any of the methods 1000, 1100, 1200, the method may further include orienting the system of modular structural panels horizontally for use as a floor. In one example embodiment, this may be performed on an ongoing basis when the system of modular structural panels is constructed across a floor. In this example, the system of modular structural panels may be constructed on top of an existing floor or subfloor. In another example embodiment, this may be performed on an ongoing basis, such as by inserting structural framing members such as 2×8 floor joists simultaneously in each channel 180, such as Figure 1 As shown. In the example described, the system modular structural panels can be made into floors. Other horizontally oriented components and assembly methods are also possible.
[0078] In at least one embodiment of any of methods 1000, 1100, 1200, the method may also include vertically orienting the system of modular structural panels for use as a wall. In one example embodiment, this may be performed by systematically vertically building the wall by erecting a series of vertical building members (such as 2×4 wall studs) and sliding each vertical building member through each channel 180 of each modular structural panel. In another example embodiment, this may be performed by first assembling the system of modular structural panels horizontally, inserting the vertical building members into each channel 180 while still oriented horizontally, and then erecting the completed wall by lifting the system of modular structural panels from the horizontal orientation to the vertical orientation. Other vertically oriented assemblies and assembly methods thereof are also possible.
[0079] Reference now Fig.10 , wherein an example embodiment of a system of modular structural panels is shown, wherein substantially similar Figure 1Multiple modular structural panels of the modular structural panel 100 are stacked for storage and / or use as a pallet. In the illustrated embodiment, the support members of the upper modular structural panel and the recesses of the lower modular structural panel can be complementary, so that the upper support member nests in the lower recess. For example, the support member 650b of the modular structural panel 600 nests in the narrowed recess 720b of the modular structural panel 700 below it. The support member 650c is similarly nested in the narrowed recess 720c. This can provide various benefits, such as improved shipping stability and the strength and stability of a multi-layer wall or floor system of modular panels.
[0080] In at least one embodiment, nesting the structural panel 600 into the structural panel 700 can allow nesting capabilities to a depth as low as 3 / 4 inch. This can allow for reduced requirements for shipping space because a greater number of structural panels can be nested in a space previously used for a smaller number of structural panels. For example, the structural panel can have dimensions of 40 inches by 48 inches. In a more traditional case, the structural panel can be stacked 40 structural panels in height across 27 lifts, which is the lifting capacity of a 53-foot trailer. This can result in a maximum of 1,080 structural panels per trailer. When considering the nesting capabilities of the structural panels 600, 700 at a depth as low as 3 / 4 inch, 146 structural panels can be stacked in height across 27 lifts. This can result in up to 3,982 structural panels per trailer. The increase in shipping trailer capacity can reduce the impact of transportation on the environment as well as transportation costs.
[0081] In at least one embodiment, the described method may further include orienting a first system of modular structural panels horizontally to function as a floor as described herein, and orienting a second system of modular structural panels vertically to function as a wall as described herein. The first system of modular structural panels and the second system of modular structural panels may then be connected, for example, using a plurality of 90 degree connectors inserted into adjacent narrowed recesses of adjacent support members. Such as by Fig.13 Other ways of connecting one or more intermediate building members 194 shown in FIG. 1 are also possible.
[0082] Reference now Fig.13 , which shows a first system 800 of modular structural panels oriented for use as floors and a second system 900 of modular structural panels oriented for use as walls. Also shown are vertical frame members 190 and horizontal frame members 192, which can be seen passing through the vertical frame members 190 and horizontal frame members 192 as shown. Figure 1 Channel 180 is depicted in FIG.
[0083] In addition to being used as floors, walls, or pallets, other uses are possible. For example, one or more modular structural panels can enclose all recesses to create a substantially flat surface for use as a table, bed, or other furniture. In another example, a system of modular structural panels can be oriented at an angle, such as for use as a roof.
[0084] Manufacturing method
[0085] In at least one embodiment, each modular structural panel can be made of a mixture of resin and agricultural waste material. The ratio of resin to agricultural waste material can be at least 50% resin to at least 50% agricultural waste material. For example, the ratio can be 50% resin to 50% agricultural waste material, or 75% resin to 25% agricultural waste material. Other ratios are also possible. The ratio can depend on the desired physical, chemical, and biological properties of the modular structural panel.
[0086] In some embodiments, the agricultural waste material can be a plurality of corn fibers extracted from corn husks. The plurality of corn fibers can be of any length and orientation. For example, the plurality of corn fibers can be long continuous strands. The plurality of corn fibers can also be unidirectionally oriented, bidirectionally oriented, or multidirectionally oriented across the flat surface. In another example, the plurality of corn fibers can be short segments. In such embodiments, the plurality of corn fibers can be randomly oriented across the flat surface. The length and orientation of the plurality of corn fibers can be substantially similar or different in the plurality of support members and / or beams than in the flat surface. This may depend, for example, on whether the features are formed integrally or formed separately and subsequently assembled.
[0087] In some embodiments, the agricultural waste material can be a plurality of hemp fibers (a plurality of hempfibers). The hemp fibers can be of any length and orientation. For example, the hemp fibers can be long continuous strands. The hemp fibers can also be unidirectionally oriented, bidirectionally oriented, or multidirectionally oriented over the entire flat surface. In another example, the hemp fibers can be short segments. In such embodiments, the hemp fibers can be randomly oriented over the entire flat surface. The length and orientation of the hemp fibers can be substantially similar or different in a plurality of support members and / or stringers than in the flat surface. This may depend, for example, on whether these features are integrally formed or individually formed and subsequently assembled.
[0088] In at least one embodiment, each modular structural panel can be compression molded. This may facilitate the manufacture of multiple corn fibers of arbitrary length and / or orientation.
[0089] In at least one embodiment, modular structural panel 100 may be integrally formed.
[0090] In at least one embodiment, each modular structural panel may be injection molded. This may be limited to manufacturing with multiple short, randomly oriented corn fiber segments.
[0091] In one embodiment, a product design is formed based on a modular structural panel. A mold can be made to form a negative cavity for the product design. For example, the negative cavity of the mold formed can have the size and shape of the modular structural panel. In another example, the negative cavity can have the size and shape of a connector (such as connectors 130a, 130b) or a cover (such as cover 140a, 140b).
[0092] In some embodiments, there can be multiple molds used to form a complete mold for a modular structural panel. For example, a modular structural panel can be molded from four separate, smaller molds. In the described embodiments, after injection molding, the individual pieces can be joined together to form the modular structural panel. For example, the pieces can be snapped, bolted, threaded, or fastened together in any other manner to form a complete structural panel. In some embodiments, the modular structural panel can be manufactured from as few as one mold to as many individual molds as are required to form the modular structural panel.
[0093] The mold can be made of specific grades of steel and aluminum designed to withstand a large number of heating and cooling cycles (such as 6063 aluminum, P20 steel, H13 steel, 420 stainless steel or any other steel or aluminum grade). In some embodiments, the mold consists of two parts to be clamped together.
[0094] The manufacturing molds for modular structural panels, connectors and / or covers can be placed in an injection molding machine. The injection molding machine can be made of a hopper, barrel, injection ram / rotating screw, heating equipment, movable mold and ejector along with the manufactured molds.
[0095] To begin the injection molding process, the manufactured mold can be securely enclosed in the clamping unit of the injection molding machine. The clamping unit can hold the manufactured mold halves together to keep the mold airtight when the panel material is injected. The clamping unit can be used to open and close the mold and eject the formed part. In some embodiments, the clamping unit is a toggle type. In some embodiments, the clamping unit is a straight hydraulic type.
[0096] Once the manufactured mold is clamped in the clamping unit, the panel material can be fed into the injection molding machine and conveyed or spiraled toward the mold. The panel material fed into the injection molding machine can be such as to fill only the amount of the manufactured mold. The panel material can be any mixture of the resin and agricultural waste material as disclosed. In some embodiments, the panel material can be in the form of pellets.
[0097] The panel material can travel through the barrel of the injection molding machine via the injection ram / rotating screw toward the mold. The heating zone in the barrel can heat the panel material due to the increased temperature and compress it into a molten material.
[0098] The panel material in a molten state can then be inserted into the mold within the clamping unit. Once the panel material contacts the inside of the mold surface, the cooling process begins. The cooling process can solidify the shape and rigidity of the manufactured part. The clamping unit can hold the manufactured part in place until the required cooling time has passed.
[0099] Once the cooling time has passed, the injection molding machine can eject the manufactured part from the mold using the ejection system. The necessary ejection force can be used to push the part out of the mold.
[0100] Once the manufactured part is ejected from the injection molding machine, the process can be repeated as many times as needed.
[0101] Physical, chemical and biological properties
[0102] The physical, chemical, and biological properties of the modular structural panels described herein may vary depending on the ratio of resin to fiber. For example, a greater ratio of resin to fiber may have better / worse chemical and biological properties, but better / worse physical properties.
[0103] Various embodiments are described herein by way of example only. Various modifications and variations may be made to these exemplary embodiments without departing from the spirit and scope of the present invention, which is limited only by the appended claims.
Claims
1. A system of modular structural panels, comprising: at least two modular structural panels for supporting a load; as well as at least one connector for securing two or more modular structural panels together; wherein each modular structural panel has a planar surface defining a first plane; wherein each modular structural panel has a plurality of narrowed recesses, at least one narrowed recess being located proximate an edge of said planar surface; Each connector has a protrusion shaped and sized so that the protrusion engages in the narrowed recess to secure two or more adjacent modular structural panels together.
2. A system of modular structural panels according to claim 1, wherein each modular structural panel further comprises a plurality of support members extending opposite to the planar surface for supporting the modular structural panel, each support member extending to a second plane substantially parallel to the first plane.
3. A system of modular structural panels according to claim 2, wherein the planar surface and the plurality of support members of each modular structural panel are integrally formed.
4. A system of modular structural panels according to claim 3, wherein each modular structural panel comprises a mixture of resin and agricultural waste material.
5. A system of modular structural panels according to claim 4, wherein the mixture of resin and agricultural waste material comprises a ratio of at least 50% resin to at least 20% agricultural waste material.
6. A system of modular structural panels according to claim 5, wherein the agricultural waste material comprises a plurality of hemp fibers.
7. A system of modular structural panels according to claim 6, wherein the plurality of hemp fibers are oriented unidirectionally across the planar surface.
8. The system of modular structural panels of claim 6, wherein the plurality of hemp fibers are bi-directionally oriented across the planar surface.
9. The system of modular structural panels of claim 6, wherein the plurality of hemp fibers are multi-directionally oriented across the planar surface.
10. The system of modular structural panels of claim 6, wherein the plurality of hemp fibers are randomly oriented across the planar surface.
11. A system of modular structural panels according to any one of claims 7 to 10, wherein each modular structural panel is compression moulded.
12. A system of modular structural panels according to any one of claims 7 to 10, wherein each modular structural panel is injection moulded.
13. A system of modular structural panels according to claim 11 or 12, wherein the plurality of narrowed recesses further comprises at least one narrowed recess located proximate a corner of the planar surface.
14. A system of modular structural panels according to any one of claims 11 to 13, wherein the plurality of narrowed recesses further comprises at least one narrowed recess located proximate an interior of the planar surface.
15. A system of modular structural panels according to any one of claims 13 to 14, wherein each support member corresponds to a narrowing recess.
16. A system of modular structural panels according to claim 15, wherein each narrowed recess extends through the planar surface to form a cavity within the corresponding support member.
17. A system of modular structural panels according to claim 16, further comprising at least one cover plate to enclose at least one narrowed recess independently of an adjacent narrowed recess, each cover plate being shaped and sized so that each cover plate is received in each narrowed recess so that when engaged, the cover plate is substantially coplanar with the first plane of each modular structural panel.
18. A system of modular structural panels according to claim 17, wherein each cavity has at least one slot, and each slot is shaped and sized so that each slot receives a protrusion of each connector with an interference fit to secure two or more modular structural panels together.
19. A system of modular structural panels according to claim 18, wherein each cover plate has at least one protrusion, the at least one protrusion being shaped and sized so that the at least one protrusion engages each narrowed recess to secure the cover plate in place.
20. A system of modular structural panels according to claim 19, wherein the at least one slot of each cavity is further shaped and sized so that the at least one slot receives a protrusion of each cover panel with an interference fit to secure the cover panel in place.
21. A system of modular structural panels according to claim 17, wherein each connector has at least four protrusions, and the shape and size of the at least four protrusions are designed so that the at least four protrusions engage each adjacent narrowed recess to secure two or more modular structural panels together.
22. A system of modular structural panels according to claim 21, wherein each cavity has at least one track extending through the cavity, and the shape and size of each track are designed so that each track is received between two protrusions of each connector with an interference fit to secure two or more modular structural panels together.
23. A system of modular structural panels according to claim 22, wherein each cover plate has at least two protrusions, and the at least two protrusions are shaped and sized so that the at least two protrusions engage each narrowed recess to secure the cover plate in the appropriate position.
24. A system of modular structural panels according to claim 23, wherein the shape and size of the at least one track of each cavity are further designed so that the at least one track is received between the two protrusions of each cover plate with an interference fit to fix the cover plate in an appropriate position.
25. A system of modular structural panels according to claim 22 or 24, wherein each modular structural panel further comprises at least one first group of beams extending opposite to the planar surface between at least two adjacent support members for structural reinforcement of the planar surface.
26. The system of modular structural panels of claim 25, wherein each modular structural panel further comprises a second set of stringers extending opposite the planar surface, the second set of stringers being substantially perpendicular to the first set of stringers.
27. A system of modular structural panels according to claim 26, wherein the first set of stringers and the second set of stringers of each modular structural panel intersect.
28. A system of modular structural panels according to claim 27, wherein the second set of beams includes at least two beams intersecting each support member, each of the beams being substantially parallel and spaced apart so as to define a channel shaped and sized to receive one of a plurality of structural building members.
29. A system of modular structural panels according to claim 28, wherein each modular structural pallet functions as one or more of a pallet, a floor element or a wall element.
30. A method of assembling a system of modular structural panels, comprising: positioning a first modular structural panel as described in any one of claims 1 to 29 adjacent to a second modular structural panel as described in any one of claims 1 to 29; butting a first edge of the first modular structural panel against a first edge of the second modular structural panel; substantially aligning each edge support member and each corner support member along a first edge of the first modular structural panel with each edge support member and each corner support member along a first edge of the second modular structural panel to form a first plurality of contiguous narrowed recesses; as well as The first modular structural panel is removably connected to the second modular structural panel along the abutting edges by inserting at least one connector into each adjoining narrowed recess.
31. The method of claim 30, further comprising covering the narrowed recesses of adjacent narrowed recesses of each support member independent of the first modular structural panel and the second modular structural panel by inserting at least one cover panel into each narrowed recess.
32. The method of claim 31 further comprising slidably engaging at least one protrusion of the connector along the abutting edge in at least one slot in the cavity of each aligned support member to secure the first modular structural panel to the second modular structural panel.
33. The method of claim 32 further comprising slidably engaging at least one protrusion of the cover panel in at least one slot in the cavity of each support member except the support members along the abutting edges to secure each cover panel in place.
34. The method of claim 31 further comprising slidably engaging the at least one rail within a cavity of each aligned support member along the abutting edge between at least two protrusions to secure the first modular structural panel to the second modular structural panel.
35. The method of claim 34 further comprising slidably engaging the at least one track within a cavity of each support member except along the abutting edge between at least two protrusions to secure each cover panel in place.
36. The method of claim 33 or 35, further comprising at least one further modular structural panel, and the method further comprising: The method defined in claims 33 to 35 is repeated for each further modular structural panel.
37. The method of claim 36, further comprising orienting the system of modular structural panels horizontally for use as a floor.
38. The method of claim 36, further comprising vertically orienting the system of modular structural panels for use as a wall.
39. The method of claim 37 or 38, further comprising inserting the plurality of structural building members into each channel to structurally reinforce the system of modular structural panels.
40. The method of claim 36, further comprising orienting a first system of modular structural panels horizontally for use as floors and vertically orienting a second system of modular structural panels for use as walls, the first system of modular structural panels being connected to the second system of modular structural panels using a plurality of 90 degree connectors inserted into adjacent narrowed recesses of adjacent support members.