U.S. patent application number 11/881858 was filed with the patent office on 2009-02-05 for panels and a method of making.
Invention is credited to Khatchik Chris Khatchikian.
Application Number | 20090031661 11/881858 |
Document ID | / |
Family ID | 40304629 |
Filed Date | 2009-02-05 |
United States Patent
Application |
20090031661 |
Kind Code |
A1 |
Khatchikian; Khatchik
Chris |
February 5, 2009 |
Panels and a method of making
Abstract
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.
Inventors: |
Khatchikian; Khatchik Chris;
(Burbnak, CA) |
Correspondence
Address: |
PETER GANJIAN
3146 NORTH VERDUGO ROAD
GLENDALE
CA
91208-1665
US
|
Family ID: |
40304629 |
Appl. No.: |
11/881858 |
Filed: |
July 30, 2007 |
Current U.S.
Class: |
52/425 ;
52/745.19 |
Current CPC
Class: |
E04C 2/044 20130101 |
Class at
Publication: |
52/425 ;
52/745.19 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
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.
Description
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] This invention relates to construction and, more
particularly construction panels and a method of their manufacture
and assembly.
[0003] (2) Description of Related Art
[0004] 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.
[0005] 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.
[0006] 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 INVENTION
[0007] One 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] A further optional aspect of the present invention provides
a prefabricated modular panel, wherein the filler material is
comprised of Expandable Polystyrene (EPS) material.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] 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.
[0021] A further optional aspect of the present invention provides
a method for prefabricating modular panels, wherein the expansion
substance is penthane.
[0022] 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.
[0023] 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.
[0024] 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.
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] 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.
[0030] Referring to the drawings in which like reference
character(s) present corresponding part(s) throughout:
[0031] FIG. 1A is an exemplary illustration of a prefabricated
modular panel in accordance with the present invention;
[0032] FIG. 1B is an exemplary illustration of A framework of the
prefabricated modular panel illustrated in FIG. 1A in accordance
with the present invention;
[0033] FIGS. 1C and 1D are exemplary plan view illustrations of
lattices that make the framework of the prefabricated modular panel
in accordance with the present invention;
[0034] FIG. 1E is an exemplary illustration of two triangular
lattices placed laterally in opposite orientation;
[0035] FIGS. 1F and 1G are exemplary illustrations of methods for
coupling a third zigzag member to the first and second elongated
members in accordance with the present invention;
[0036] FIG. 2A is an exemplary flow chart illustration of a
manufacturing process of a filler material of the prefabricated
modular panel in accordance with the present invention;
[0037] FIG. 2B is an exemplary flow chart illustration of
manufacturing process of molding the prefabricated modular panel
using the filler material in accordance with the present
invention;
[0038] FIG. 2C is an exemplary schematic illustration of a
manufacturing equipment used to produce the filler material;
[0039] FIG. 3A is an exemplary top-view perspective illustration of
a mold in accordance with the present invention, and FIG. 3B is an
enlarged close-up view of the same;
[0040] FIG. 3C is an exemplary front-cross-sectional view of the
mold in the direction A-A illustrated in FIG. 3A;
[0041] FIG. 3D is an exemplary top-view perspective illustration of
the mold illustrated in FIG. 3A, with the placement of lattices
within the mold in accordance with the present invention;
[0042] FIG. 3E is an exemplary front-cross-sectional view of the
mold in the direction B-B illustrated in FIG. 3D;
[0043] FIG. 4A is an exemplary front cross-sectional illustration
of the prefabricated modular panel illustrated in FIG. 1A;
[0044] FIG. 4B is an exemplary lateral cross-sectional views of the
prefabricated modular panel that uses triangular lattices in
accordance with the present invention;
[0045] FIG. 4C is an exemplary illustration of the prefabricated
modular panel illustrating one or more transversally oriented
utility holes in accordance with the present invention;
[0046] FIG. 4D is an exemplary perspective cross sectional view of
the prefabricated modular panel along the lines C-C illustrated in
FIG. 4C;
[0047] FIG. 5A is an exemplary illustration of a prefabricated
modular panel used as a wall, placed within a foundation in
accordance with the present invention, and FIG. 5B is an enlarged
illustration of the same; and
[0048] FIG. 5C is an exemplary illustration of connection of the
prefabricated modular panel together to form the four corners of a
housing or chamber, using beams in accordance with the present
invention; and
[0049] FIG. 5D is an exemplary illustration of details of one of
the four corners illustrated in FIG. 5C.
DETAILED DESCRIPTION OF THE INVENTION
[0050] 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.
[0051] 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. FIG.
1A is an exemplary illustration of a prefabricated modular panel in
accordance with the present invention. As illustrated, the present
invention provides a prefabricated modular panel 100, comprising a
framework 106 (FIG. 1B) that includes a plurality of lattices 102
coupled with one another in parallel by a solidified filler
material 104 within a mold to form a single piece, unitary
prefabricated modular panel 100.
[0052] FIG. 1B is an exemplary illustration of the framework 106 of
the prefabricated modular panel 100 in accordance with the present
invention, with the filler material 104 removed. As illustrated,
the framework 106 is comprised of a plurality of lattices 102 that
are coupled with one another by the solidified filler material 104
(illustrated in FIG. 1A). The plurality of lattices 102 are
transversely coupled with one another only by the solidified filler
material 104 formed inside a mold to form the prefabricated modular
panel 100.
[0053] FIGS. 1C and 1D are exemplary plan view illustrations of
lattices 102 that make the framework 106 of the prefabricated
modular panel 100 in accordance with the present invention. As
illustrated, each lattice 108 and or 109 of the plurality of
lattices 102 is comprised of a first elongated member 110 and a
second elongated member 112 that are spaced apart and juxtapose
laterally (one on top (110) and the other in bottom (112)) in
parallel, forming an axial length 114 of the lattice 108 and or
109. As further illustrated, the lattice 108 and or 109 further
includes a third member 116 substantially transversally oriented at
an angle .theta. along the axial length 114 of the lattice 108 and
or 109. The third member 116 couples the first elongated member 110
with the second elongated member 112 to form the lattice 108 and or
109, with the plurality of lattices 102 forming the framework
106.
[0054] As illustrated in FIG. 1C, the third member 116 may comprise
of a single piece elongated unit having a zigzag configuration that
spans longitudinally along the axial length 114 of the lattice 108.
The third member 116 couples the first elongated member 110 with
the second elongated member 112 at vertexes 120 that form the
angles .theta. (less than 90.degree.) in alternative directions of
the zigzag configuration. FIGS. 1F and 1G are exemplary
illustrations of methods for coupling the third zigzag member 116
to the first and second elongated members 110 and 112. As best
illustrated in FIG. 1F, one specific, non-limiting exemplary
technique for manufacture of lattice 108 is to place the respective
first and second elongated members 110 and 112 in parallel in
relation to one another and place the third member 116 on top of
the respective first and second elongated members 110 and 112, and
weld them. Another method is to simply weld the apex of the vertex
of every angle of the zigzag configuration of the third member 116
to the surface (facing inside the lattice) of the respective first
and second elongated members 110 and 112, as illustrated in FIG.
1G.
[0055] As illustrated in FIG. 1D, the third member 116 is comprised
of a plurality of single pieces that are transversally oriented
along the axial length 114 of the lattice 109. Each single piece
116 having a first extremity 130 and a second extremity 132, with
the first extremity 130 jointed to the first elongated member 110
and the second extremity 132 jointed to the second elongated member
112, with each single piece 116 oriented substantially
perpendicular to the respective first and second elongated members
110 and 112.
[0056] 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 FIGS. 1A and 1B, the
plurality of lattices 102 are juxtapose laterally in parallel and
are coupled with one another by a solidified filler material 104
(within a mold) forming a single piece, unitary prefabricated
modular panel 100.
[0057] 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.
[0058] As further illustrated in FIG. 1E, triangular lattices 108
may be juxtaposed laterally in parallel in upside down orientation
to form the framework 106. That is, the vertices 120 of lattice
108A is placed parallel adjacent the bases 122 of the other lattice
108B, the combination of which can be optionally used with ladder
lattices 109, all of which provide added structural strength.
Accordingly, any combination and permutations of lattices 108, 109
or any other types (e.g., true trusses) or in any orientations may
be juxtaposed laterally in parallel with one another to form the
framework 106 for added structural strength and integrity.
[0059] FIG. 2A is an exemplary flow chart illustration of a
manufacturing process of a filler material of the prefabricated
modular panel in accordance with the present invention. In general,
a preferred, but non-limiting and exemplary filler material used
with the present invention is Expandable Polystyrene (EPS). EPS and
the production of EPS are well known, and do not form the inventive
part of the present invention. Accordingly, any method or
manufacturing process that is used to produce EPS will work with
the present invention.
[0060] FIG. 2C is an exemplary schematic illustration of one
exemplary method for production of EPS and its use as the filler
material of the prefabricated modular panel. In general, the raw
material (raw EPS) used comes in the form of beads and hence, needs
to be expanded before its use as the filler material 104 of the
present invention. According, as part of the production of EPS, a
pre-expansion process as the illustrated functional acts 201 (of
FIG. 2A) is needed before its use. Pre-expanding the raw EPS beads
includes reducing the density of the beads 202 by soaking the beads
202 within an expansion substance such as penthane, and the
addition of heat. In particular, the raw material (raw EPS beads)
202 is delivered by a transport system 208 into a chamber 212 of a
pre-expander unit 210 that includes penthane wherein the beads are
soaked, and heat is applied therein the chamber 212 to expand and
reduce the density of the beads 202. The exemplary process is a
continuous type, which means that there is a continuous flow of
fresh beads 202 into the expander unit 210. As the beads 202 are
expanded, they simply overflow into the dryer 214 (similar to
overflow of pop corn when it is heated and expanded). As
illustrated in the functional act 203, the still wet expanded EPS
is moved into a dryer, where the growing or expansion process stops
because no more heat is applied to the now expanded beads. The
still wet expanded material is moved into the dryer fluid bed 214,
where a blower 216 applies dry air to the wet material to dry the
wet EPS. As indicated in the functional act 205, the now dried and
expanded EPS is moved into storage units or silos 222 for storage
and maturity via a pipe work 220. In general, the capacity of the
production of EPS should always be higher than the actual use of
material by molding machines 240, and further, certain
manufacturers of EPS require a minimum maturity of 24 hours before
the use of EPS. Accordingly, silos offer a capacity higher then the
daily maximum demand. As further illustrated in the functional act
207, molding machines 240 of the present invention are then coupled
to the silos 222 via connecting hoses 230, where EPS is transported
therein and used.
[0061] FIG. 2B is an exemplary flow chart illustration of
manufacturing process of molding the prefabricated modular panel
using the filler material in accordance with the present invention.
As illustrated at functional act 211, the lattices 102 are placed
inside the channels of molds 240. FIGS. 3A to 3E are various
exemplary views of the molds 240 of the present invention. FIG. 3A
is an exemplary top-view perspective illustration of a mold in
accordance with the present invention, and FIG. 3B is an enlarged
close-up view of the same. FIG. 3C is an exemplary
front-cross-sectional view in the direction A-A illustrated in FIG.
3A. FIG. 3D is an exemplary top-view perspective illustration of
the mold illustrated in FIG. 3A, with the placement of lattices
within the mold in accordance with the present invention. FIG. 3E
is an exemplary front-cross-sectional view in the direction B-B
illustrated in FIG. 3D.
[0062] As illustrated in FIGS. 3A to 3C, the mold 240 is comprised
of a chamber with a top piece 302 and a bottom piece 304, with the
bottom piece 302 having a bottom piece cavity 310 and a top piece
302 with a top piece cavity 312. The respective bottom and top
piece cavities 310 and 312 are configured to mold any size and
shape prefabricated modular panel. In this exemplary instance, the
mold cavities 310 and 312 are commensurately contoured for
manufacture of prefabricated modular panel 100 illustrated in FIG.
1A. As illustrated, in this exemplary instance, the bottom piece
cavity 310 is the mirror image of the top piece cavity 312. Both
cavities have interior surrounding walls 314 and 316, configured to
form the lateral sides or edges of the prefabricated modular panel
100. As further illustrated in FIGS. 3A to 3C, the mold 240 further
includes one or more parallel channels 308 that extend
longitudinally, oriented along the axial length 320 of the mold
240. As indicated by the functional act 211 in FIG. 2B and as best
illustrated in FIG. 3D, each lattice 102 is placed within a channel
308 of the one or more channels of the mold 240, with the channels
308 allowing the respective first and second elongated members 110
and 112 of the plurality of lattices 102 to be secured upright
(longitudinally parallel with ground), laterally within the
channels 308. Accordingly, as best illustrated in FIG. 3E, the
lattices 102 are placed in between the respective top and bottom
pieces 302 and 304 of the mold 240 and housed within the channels
308, with one of the first and second elongated members 110 and 112
of the lattices 102 housed in channels 308 of the bottom piece 304
and the other member housed in the channel 308 of the top piece
302. The respective top and the bottom pieces 302 and 304 of the
mold are then closed, ready for injection of the filler material.
It should be noted that any type of mold may be used so long as
there is means to uphold the plurality of lattices therein the
mold. For example, the mold 240 may comprise of a single piece mold
rather than two pieces (top and bottom), with the single piece mold
having a side-opening door to allow loading of lattices 102 and
unloading of the prefabricated modular panels 100.
[0063] As illustrated in FIG. 2B, at the functional act 213, the
filler material (EPS) is transferred into the molds 240 by
well-known mechanisms through one or more apertures 306 (the
location of the apertures 306 may be varied). In general, injection
of EPS inside the molds 240 fills the void spaces 324 inside the
cavities 310 and 312, which are in between the lattices 102. As
further illustrated in FIG. 2B, at functional act 215 heat is
applied to the molds 240 by a heating and cooling system 250, where
the filler material EPS is expanded and bonds (physical bonding)
with the lattices to form the prefabricated modular panel 100.
Although not illustrated, the mold may comprise additional
apertures for the application of heat therein. As illustrated in
the functional act 217, the mold 240 is then cooled by the heating
and cooling system 250 and the final prefabricated modular panel
100 is ejected from the mold 240 (functional act 219) ready for
use. Other methods of manufacturing prefabricated modular panels
100 in accordance with the present invention may include
assembly-line type manufacturing methodology.
[0064] FIGS. 4A to 4D are various exemplary views of the finally
prefabricated modular panel 100 of the present invention. FIG. 4A
is an exemplary front cross-sectional illustration of the
prefabricated modular panel 100 illustrated in FIG. 1A. FIG. 4B is
an exemplary lateral cross-sectional views of the prefabricated
modular panel 100 that uses triangular lattices. FIG. 4C is an
exemplary illustration of the prefabricated modular panel 100
illustrating one or more transversally oriented utility holes. FIG.
4D is an exemplary perspective cross sectional view along the lines
C-C illustrated in FIG. 4C. As illustrated, the prefabricated
modular panel 100 is comprised of the framework 106 (FIG. 1B) that
includes the plurality of lattices 102 coupled with one another in
parallel by a solidified filler material (EPS) 104 forming a single
piece, unitary prefabricated modular panel 100. As best illustrated
in FIGS. 4A and 4B, the prefabricated modular panel 100 includes a
spacing 402 in between the first elongated member 110 and the
solidified filler material 104 and spacing 404 in between the
second elongated member 112 and the solidified filler material 104.
The depth of the spacing is equal to the depth of the channels 308
of the molds 240. Accordingly, as illustrated in the
cross-sectional view in FIG. 4A and lateral view in FIG. 4B, the
lattices 102 are not fully encapsulated by the filler material
(EPS) 104 and hence, the respective first and the second elongated
members 110 and 112 protrude out and are visible. As further
illustrated in FIGS. 4C and 4D, the prefabricated modular panel 100
may further include one or more transversally oriented utility
through holes 406 aligned along an axial length 320 of the
prefabricated modular panel 100, which also reduce the overall
weight of the panels 100, but can be used for housing and running
utility wiring through the holes 320.
[0065] FIGS. 5A to 5D are various view of the prefabricated modular
panel used for a building a structure in accordance with the
present invention. FIG. 5A is an exemplary illustration of a
prefabricated modular panel used as a wall, placed within a
foundation, and FIG. 5B is an enlarged illustration of the method
of the prefabricated modular wall panel within the foundation. FIG.
5C is an exemplary illustration of connection of one or more
prefabricated modular panels together to form a housing or chamber
in accordance with the present invention, and FIG. 5D is an
exemplary illustration of details of one of the corners of the
housing or chamber illustrated in FIG. 5C. As illustrated in FIGS.
5A to 5D, one or more prefabricated modular panels 100 are
positioned within a foundation 502 of the structure 504, vertically
juxtaposed and coupled with one another with wiring 516. The one or
more prefabricated modular panels 100 are vertically juxtaposed
within a foundation 502 by excavating a channel with desired
dimensions, and modifying the prefabricated modular panel 100 by
partially removing the filler material 104 thereof at a lower
section 506 of the prefabricated modular panel 100 to expose the
lattices 102. Thereafter, inserting the modified prefabricated
modular panel 100 with the exposed lattices 102 inside the ditch,
and coupling the vertically juxtaposed modified prefabricated
modular panel by wiring 516 that spans a surface area of all
juxtaposed panels, including inside the ditches. The wiring 516
(which could be a simple "chicken wire") is coupled with the first
and the second elongated members 110 and 112 (through in between
the spacing 402 and 404) of the prefabricated modular panels 100.
The coupling of the wire 516 with the panels 100 may be done by a
variety of fastener mechanism. Thereafter, pouring concrete 514
within the ditches and through the spaces 402 and 404, with the
concrete curing and coupling the modified prefabricated modular
panel, forming a single piece unitary structure. The prefabricated
modular panels may finally be covered with external covering, such
as stucco. As best illustrated in FIGS. 5C and 5D, elongated rebar
or metal beams 520 and 522 may be used at the corners 512 of the
structure 504 to create a multi-story building, with the rebar or
metal beams 520 and 522 filled with concrete 514.
[0066] 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.
[0067] 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.
[0068] 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.
[0069] 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.
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