Method for combining polymeric panels and steel sections in modular construction panels

Abstract

The polymeric building panel 1 is treated such that it can interlock securely with a C section of a steel material to form a composite lightweight construction. The polymer block may be expanded polystyrene. The treatment may include creating a groove 3. The treatment may use thermal, chemical, radiation or other methods to modify the ends 5 of the panel such that the anterior and posterior surfaces become brittle and hard.

Description

This invention relates to the fields of construction and manufacturing, with a particular emphasis on a method for fabricating modular building panels that are applicable for use as walls, floors, beams and ceilings. The process entails the integration of polymeric panels with steel C sections and U sections, in addition to utilizing a range of compatible steel sections with thicknesses varying from 0.2mm to 2mm. This methodology facilitates the production of structurally sound and versatile modular components, optimized for a variety of construction applications. In the realm of modular building construction, there is a significant demand for materials that are not only lightweight and strong but also simple to assemble. However, traditional approaches to integrating insulating materials with structural components frequently encounter challenges. These include issues with structural stability, complications in the assembly process, and inefficiencies in thermal insulation. Addressing these limitations is crucial for advancing the effectiveness and practicality of modular construction techniques. The present invention introduces a unique manufacturing methodology that enables the effective coupling of commercially available polymeric panels 1 often referred to as (XPS) expanded polystyrene to steel C sections 2 and equivalent steel profiles. This novel technique substantially enhances the quality and performance of a modular building panel, which are critical components in the assembly of modular structures. Through this process, the integration of polymeric panels 1 with lightweight steel frameworks is optimized, resulting in superior structural integrity and efficiency in modular construction applications. This inventive method distinguishes itself through an innovative method of processing polymeric panels 1. In particular, it involves the meticulous fabrication of a groove 3 along the full length of the polymeric panel 1, engineered to correspond precisely with the width of the lip 4 found on a steel ‘C’ section 2 or other compatible steel sections. For conventional lightweight gauge C-section steel 2, this lip 4 measures approximately 0.5mm in width. The depth of the groove 3 is calibrated to align with that of the lightweight gauge C-section steel 2, generally about 1cm. This groove 3 is executed with exacting accuracy across the full length of the polymeric panel 1. Utilizing targeted thermal, chemical, radiation or any other application to distort the grooved peripheries 5 of the polymeric panel's 1 lateral extents facilitates a systematic and regulated modification of the material characteristics cauterizing these specified zones, eliciting contraction, morphological changes, and increased material density. This meticulous and focused adjustment of the polymeric panel's 1 exterior surfaces guarantees stringent adherence to the geometric contours and specifications of the steel C sections 2 or similar steel elements. This process not only ensures a precise fit but also enhances the composite material's structural coherence and integration with steel frameworks. Consequently, this technique achieves an optimal interlocking fit, significantly bolstering the composite structure's overall structural integrity This specialized treatment is uniformly executed along the entire longitudinal extent of the polymeric panel's 1 lateral faces. Furthermore, it is meticulously administered to designated segments of the anterior and posterior surfaces 5, wherein the dimensions of the treated regions are exactly tailored to correspond with the width of the specific steel section deployed in the construction. This methodical approach ensures a consistent and precise modification of material properties across critical areas of interaction between the polymeric panels 1 and steel structural components. The regions of the panel 5 subjected to thermal, chemical, radiation or any other distortion method undergoes a metamorphosis, becoming rigid and brittle. This alteration optimally prepares them for integration with the steel C section 2 or equivalent steel profiles employed in the assembly. Subsequently, the thermally modified polymeric panel 1 is adeptly inserted into the steel C section 2, where it glides into place, meticulously occupying any voids and achieving a precise, tight engagement, thereby constituting a composite panel. This process not only facilitates a flawless union between the polymeric and steel components but also significantly enhances the structural coherence and integrity of the resultant composite panel. DESCRIPTION OF THE DRAWINGS. Fig 1. Illustrates a front view of a prepared polymeric panel. Fig 2. Illustrates a top view of a prepared polymeric panel with grooves. Fig 3. Illustrates a lateral view of a polymeric panel connected to a steel ‘C’ section. Fig 4. Illustrates a plan view of a polymeric panel connected to a steel ‘C’ section.

Claims

Claim 1. The described unique manufacturing process for modular building panels involves selectively treating certain areas on a polymeric panel's surface to interlock securely with a steel ‘C’ section or similar steel section to form a composite building panel for use in lightweight modular construction.Claim 2. The building panel in Claim 1, a precision-engineered groove is meticulously fabricated along the entire length of the lateral faces of the polymeric panel.Claim 3. The building panel in Claim 1, the groove is engineered to correspond precisely with the width of the lip found on a steel ‘C’ section or other compatible steel sections.Claim 4. The building panel in Claim 1, the application of specific thermal, chemical, radiation or other methods are employed to induce a transformation within the groove and its adjacent outer edge peripheries on both the anterior and posterior surfaces becoming brittle and hard.Claim 5. The building panel in Claim 1, wherein, the grooves have been precision-engineered to facilitate the integration of a steel ‘C’ section or equivalent steel configurations.

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