Panels and a method of making
A prefabricated modular panel, comprising a framework that includes a plurality of lattices, with a lattice of the plurality of lattices comprising a first elongated member and a second elongated member that are spaced apart and juxtapose laterally parallel, forming an axial length of the lattice. Further included is a third member substantially transversally oriented at an angle along the axial length of the lattice, with the third member coupling the first elongated member with the second elongated member to form the lattice, with the plurality of lattices forming the framework. The plurality of lattices are coupled with one another in parallel by a solidified filler material forming a single piece, unitary modular panel.
(1) Field of the Invention
This invention relates to construction and, more particularly construction panels and a method of their manufacture and assembly.
(2) Description of Related Art
Conventional modular panels are well known and have been in use for a number of years. Reference is made to the following exemplary U.S. Patent Publications, including U.S. Pat. Nos. 6,226,942; 3,879,908; 6,314,704; and 4,597,813. Regrettably, most prior art conventional panels suffer from obvious disadvantages in that their method of construction is complex and costly. Further, the known methods of construction compel the use of additional parts that add to the overall cost of the resulting constructed panel.
In general, most conventional panels are built by constructing a frame of the panel using complex methodologies, which require the use of additional parts that transversely interconnect the longitudinally oriented components of the flames to make the flame a standalone unit. Completely different set of complex manufacturing techniques are then used to produce an insulation (or filler) material that will be used within the constructed frame. In addition, another set of complex manufacturing methodologies are used to combine the insulation (or filler) material with the frames, and finally, further complex methodologies are used to actually use the constructed panels for building of a structure.
Accordingly, in light of the current state of the art and the drawbacks to current panel and methodologies for panel construction and use mentioned above, a need exists for a panel and a method of manufacture and use thereof that would be simple, and that would not be labor intensive and time consuming to make and use, while providing a high structural integrity.
BRIEF SUMMARY OF THE INVENTIONOne aspect of the present invention provides a prefabricated modular panel, comprising a framework that includes a plurality of lattices. A lattice of the plurality of lattices is comprised of a first elongated member and a second elongated member that are spaced apart and juxtapose laterally parallel, forming an axial length of the lattice. Further included is a third member substantially transversally oriented at an angle along the axial length of the lattice, with the third member coupling the first elongated member with the second elongated member to form the lattice, with the plurality of lattices forming the framework. The plurality of lattices are coupled with one another in parallel by a solidified filler material forming a single piece, unitary modular panel.
An optional aspect of the present invention provides a prefabricated modular panel, wherein the third member is a single piece elongated unit having a zigzag configuration that spans longitudinally along the axial length of the lattice.
Another optional aspect of the present invention provides a prefabricated modular panel, wherein the third member couples the first elongated member with the second elongated member at vertexes that form the angles in alternative directions of the zigzag configuration.
Still another optional aspect of the present invention provides a prefabricated modular panel, wherein the third member is comprised of a plurality of single pieces that are transversally oriented along the axial length of the lattice; with each single piece having a first extremity and a second extremity, with the first extremity jointed to the first elongated member and the second extremity jointed to the second elongated member, with each single piece oriented substantially perpendicular to the first and second elongated members.
A further optional aspect of the present invention provides a prefabricated modular panel, wherein each of the plurality of lattices is a truss, with each truss member coupled with one another at a member extremities only, with no truss member continuous through a joint.
Yet a further optional aspect of the present invention provides a prefabricated modular panel, wherein the prefabricated modular panel includes one or more transversally oriented utility through holes aligned along an axial length of the prefabricated modular panel.
Another optional aspect of the present invention provides a prefabricated modular panel, wherein the plurality of lattices are coupled with one another by the solidified filler material formed inside a mold to form the prefabricated modular panel.
Yet another optional aspect of the present invention provides a prefabricated modular panel, wherein the prefabricated modular panel includes a spacing between the first elongated member and the solidified filler material and the second elongated member and the solidified filler material.
Still another optional aspect of the present invention provides a prefabricated modular panel, wherein the mold is comprised of one or more parallel channels that extend longitudinally, oriented along the axial length of the plurality of lattices, with each lattice placed within a channel of the one or more channels of the mold, with the channels allowing one of the first and second elongated members of the plurality of lattices to be secured therein the channels.
A further optional aspect of the present invention provides a prefabricated modular panel, wherein the filler material is comprised of Expandable Polystyrene (EPS) material.
Another aspect of the present invention provides a method for prefabricating modular panels, comprising juxtaposing laterally a first elongated member and a second elongated member in parallel, and coupling a third member with the first elongated member and the second elongated member, substantially transversally oriented along an axial length of the first elongated member with the second elongated member to form a lattice of the prefabricating modular panels. Thereafter, coupling one or more lattices with one another in parallel by a filler material that is solidified inside a mold to form a single piece, unitary prefabricating modular panel.
Another optional aspect of the present invention provides a method for prefabricating modular panels, wherein coupling the one or more lattices includes: pre-expanding the filler material; drying the expanded filler material; storing the dried and expanded filler material within storage facilities; placing the one or more lattices inside the mold; transferring the pre-expanded filler material into the mold; applying heat to the mold to expand the filler material, filling in void spaces within mold; cooling mold for removal of panel, and ejecting the final prefabricating modular panel.
Yet another optional aspect of the present invention provides a method for prefabricating modular panels, wherein the mold is comprised of parallel channels that extend longitudinally, oriented along an axial length of the mold, with each lattice placed within a channel of the one or more channels of the mold, with the channels allowing one of the first and second elongated members of the plurality of lattices to be secured therein the channels.
Still another optional aspect of the present invention provides a method for prefabricating modular panels, wherein pre-expanding the filler material includes soaking the filler material within an expansion substance to filler material and addition of heat to reduce density of the filler material and allow the filler material to expand.
A further optional aspect of the present invention provides a method for prefabricating modular panels, wherein the expansion substance is penthane.
Still a further optional aspect of the present invention provides a method for prefabricating modular panels, wherein drying the expanded filler material includes removing and drying the soaked and expanded filler material by application of dry air.
Another optional aspect of the present invention provides a method for prefabricating modular panels, wherein storing the dried and expanded filler material within storage facilities includes transporting the dried and expanded filler material by blowers for storage and maturing within silos.
Another aspect of the present invention provides a prefabricated modular panel used for a structure, comprising one or more prefabricated modular panels are positioned within a foundation of the structure, vertically juxtaposed and coupled with one another with wiring.
Another optional aspect of the present invention provides a prefabricated modular panel used for a structure, wherein one or more prefabricated modular panels are vertically juxtaposed within a foundation by excavating a channel with desired dimensions; modifying the prefabricated modular panel by partially removing the filler material thereof at a lower section of the prefabricated modular panel to expose the lattices; inserting the modified prefabricated modular panel with the exposed lattices inside the channels; coupling the vertically juxtaposed modified prefabricated modular panel by wiring that spans a surface area of all juxtaposed panels, including inside the channels; and pouring concrete within the channels to fill the channels, with the concrete curing and coupling the modified prefabricated modular panel, forming a single piece unitary structure.
A further optional aspect of the present invention provides a prefabricated modular panel used for a structure, wherein the wiring is coupled with the first and the second elongated members of the prefabricated modular panels.
Still a further optional aspect of the present invention provides a prefabricated modular panel used for a structure, wherein the prefabricated modular panel are finally covered with external covering.
These and other features, aspects, and advantages of the invention will be apparent to those skilled in the art from the following detailed description of preferred non-limiting exemplary embodiments, taken together with the drawings and the claims that follow.
It is to be understood that the drawings are to be used for the purposes of exemplary illustration only and not as a definition of the limits of the invention. Throughout the disclosure, the word “exemplary” is used exclusively to mean “serving as an example, instance, or illustration.” Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
Referring to the drawings in which like reference character(s) present corresponding part(s) throughout:
The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and or utilized.
The present invention provides a prefabricated modular panel and a method of manufacture and use thereof that is simple and is not labor intensive and time consuming to make and use, while providing a lightweight panel with high structural integrity.
As illustrated in
As illustrated in
Of course, each of the plurality of lattices 102 may also be comprised of a true truss, where all members of the truss are individual pieces, with each truss member coupled with one another at a member extremities only, with no truss member continuous through a joint. It should be noted that it is for the sake of brevity, clarity, convenience, and to avoid duplication that only two types of lattices 108 and 109 are illustrated, and three types described. Nonetheless, as illustrated in
In forming the framework 106 of the prefabricated modular panel 100, any combination of lattices may be juxtaposed laterally in parallel with one another. For example, a framework 106 may comprise of a plurality of lattices 102, with each individual lattice of the plurality of lattices 102 comprised of ladder lattices 109. The framework 106 may also comprise of a plurality of lattices 102, with each individual lattice of the plurality of lattices 102 comprised of triangular lattices 108. A combination of different types of individual lattices may also be used to form the framework 106. That is, both triangular lattices 108 and ladder lattices 109 may be used in combination to form the framework 106. The ladder type lattices 109 provide structural strength that counters forces that are perpendicular to the horizontal plane of the prefabricated modular panel 100, which is particularly beneficial for prefabricated modular panels 100 that are used in horizontal orientation in relation to the ground. The triangular or zigzag type lattices 108 provide structural strength that is somewhat similar to those of trusses, but simpler and easier to manufacture than a truss or a ladder lattice.
As further illustrated in
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Although the invention has been described in considerable detail in language specific to structural features and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. For example, any type of material may be used for the manufacture of the lattices, including thickness. Further, any individual panel may comprise of different types of lattices, non-limiting, non-exhaustive listing of variations may including lattice material, shape, and thickness. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention.
It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counter clockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, proximal, distal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object.
In addition, reference to “first,” “second,” “third,” and etc. members throughout the disclosure (and in particular, claims) is not used to show a serial or numerical limitation but instead is used to distinguish or identify the various members of the group.
In addition, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of,” “act of,” “operation of,” or “operational act of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.
Claims
1. A prefabricated modular panel, comprising:
- a framework;
- the framework includes a plurality of lattices;
- a lattice of the plurality of lattices is comprised of:
- a first elongated member and a second elongated member that are spaced apart and juxtapose laterally parallel, forming an axial length of the lattice;
- a third member substantially transversally oriented at an angle along the axial length of the lattice;
- the third member coupling the first elongated member with the second elongated member to form the lattice, with the plurality of lattices forming the framework;
- the plurality of lattices are coupled with one another in parallel by a solidified filler material forming a single piece, unitary modular panel.
2. The prefabricated modular panel as set forth in claim 1, wherein:
- the third member is a single piece elongated unit having a zigzag configuration that spans longitudinally along the axial length of the lattice.
3. The prefabricated modular panel as set forth in claim 2, wherein:
- the third member couples the first elongated member with the second elongated member at vertexes that form the angles in alternative directions of the zigzag configuration.
4. The prefabricated modular panel as set forth in claim 1, wherein:
- the third member is comprised of a plurality of single pieces that are transversally oriented along the axial length of the lattice;
- each single piece having a first extremity and a second extremity, with the first extremity jointed to the first elongated member and the second extremity jointed to the second elongated member, with each single piece oriented substantially perpendicular to the first and second elongated members.
5. The prefabricated modular panel as set forth in claim 1, wherein:
- each of the plurality of lattices is a truss, with each truss member coupled with one another at a member extremities only, with no truss member continuous through a joint.
6. The prefabricated modular panel as set forth in claim 1, wherein:
- the prefabricated modular panel includes one or more transversally oriented utility through holes aligned along an axial length of the prefabricated modular panel.
7. The prefabricated modular panel as set forth in claim 1, wherein:
- the plurality of lattices are coupled with one another by the solidified filler material formed inside a mold to form the prefabricated modular panel.
8. The prefabricated modular panel as set forth in claim 1, wherein:
- the prefabricated modular panel includes a spacing between the first elongated member and the solidified filler material and the second elongated member and the solidified filler material.
9. The prefabricated modular panel as set forth in claim 7, wherein:
- the mold is comprised of one or more parallel channels that extend longitudinally, oriented along the axial length of the plurality of lattices, with each lattice placed within a channel of the one or more channels of the mold, with the channels allowing one of the first and second elongated members of the plurality of lattices to be secured therein the channels.
10. The prefabricated modular panel as set forth in claim 9, wherein:
- the filler material is comprised of Expandable Polystyrene (EPS) material.
11. A method for prefabricating modular panels, comprising:
- juxtaposing laterally a first elongated member and a second elongated member in parallel;
- coupling a third member with the first elongated member and the second elongated member, substantially transversally oriented along an axial length of the first elongated member with the second elongated member to form a lattice of the prefabricating modular panels;
- coupling one or more lattices with one another in parallel by a filler material that is solidified inside a mold to form a single piece, unitary prefabricating modular panel.
12. The method for prefabricating modular panels as set forth in 11, wherein:
- coupling the one or more lattices includes:
- pre-expanding the filler material;
- drying the expanded filler material;
- storing the dried and expanded filler material within storage facilities;
- placing the one or more lattices inside the mold;
- transferring the pre-expanded filler material into the mold;
- applying heat to the mold to expand the filler material, filling in void spaces within mold;
- cooling mold for removal of panel, and
- ejecting the final prefabricating modular panel.
13. The method for prefabricating modular panels as set forth in claim 11, wherein:
- the mold is comprised of:
- parallel channels that extend longitudinally, oriented along an axial length of the mold, with each lattice placed within a channel of the one or more channels of the mold, with the channels allowing one of the first and second elongated members of the plurality of lattices to be secured therein the channels.
14. The method for prefabricating modular panels as set forth in claim 11, wherein:
- pre-expanding the filler material includes soaking the filler material within an expansion substance to filler material and addition of heat to reduce density of the filler material and allow the filler material to expand.
15. The method for prefabricating modular panels as set forth in claim 14, wherein:
- the expansion substance is penthane.
16. The method for prefabricating modular panels as set forth in claim 14, wherein:
- drying the expanded filler material includes removing and drying the soaked and expanded filler material by application of dry air.
17. The method for prefabricating modular panels as set forth in claim 16, wherein:
- storing the dried and expanded filler material within storage facilities includes transporting the dried and expanded filler material by blowers for storage and maturing within silos.
18. A prefabricated modular panel used for a structure, comprising:
- a framework;
- the framework includes a plurality of lattices;
- a lattice of the plurality of lattices is comprised of:
- a first elongated member and a second elongated member that are spaced apart and juxtapose laterally and parallel, forming an axial length of the lattice;
- a third member substantially transversally oriented along the axial length of the lattice;
- the third member coupling the first elongated member with the second elongated member to form the lattice;
- the plurality of lattices are coupled with one another in parallel by a solidified filler material forming a single piece, unitary modular panel;
- one or more prefabricated modular panels are positioned within a foundation of the structure, vertically juxtaposed and coupled with one another with wiring.
19. The prefabricated modular panel used for a structure as set froth in claim 18, wherein:
- one or more prefabricated modular panels are vertically juxtaposed within a foundation by:
- excavating a channel with desired dimensions;
- modifying the prefabricated modular panel by partially removing the filler material thereof at a lower section of the prefabricated modular panel to expose the lattices;
- inserting the modified prefabricated modular panel with the exposed lattices inside the channels;
- coupling the vertically juxtaposed modified prefabricated modular panel by wiring that spans a surface area of all juxtaposed panels, including inside the channels;
- pouring concrete within the channels to fill the channels, with the concrete curing and coupling the modified prefabricated modular panel, forming a single piece unitary structure.
20. The prefabricated modular panel used for a structure as set froth in claim 19, wherein:
- the wiring is coupled with the first and the second elongated members of the prefabricated modular panels.
21. The prefabricated modular panel used for a structure as set froth in claim 20, wherein:
- the prefabricated modular panel are finally covered with external covering.
Type: Application
Filed: Jul 30, 2007
Publication Date: Feb 5, 2009
Inventor: Khatchik Chris Khatchikian (Burbnak, CA)
Application Number: 11/881,858
International Classification: E04B 2/00 (20060101);