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.

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.