System of modular structural panels comprising agricultural waste materials and method therefor

Abstract

A system of modular structural panels and corresponding method of assembling the system, the system having at least two modular structural panels for supporting a load, and at least one connector to secure two or more modular structural panels together. Each modular structural panel has a planar surface defining a first plane. Each modular structural panel has a plurality of tapered recesses, at least one tapered recess located proximate an edge of the planar surface. Each connector has projections shaped and sized to engage in the tapered recesses so as to secure two or more adjacent modular structural panels together.

1 . A system of modular structural panels, comprising:
 at least two modular structural panels for supporting a load; and   at least one connector to secure 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 tapered recesses, at least one tapered recess located proximate an edge of the planar surface;   wherein each connector has projections shaped and sized to engage in the tapered recesses so as to secure two or more adjacent modular structural panels together.   
     
     
         2 . The system of modular structural panels of  claim 1 , wherein each modular structural panel further comprises a plurality of support members extending opposite the planar surface for supporting the modular structural panel, each support member extending to a second plane substantially parallel to the first plane. 
     
     
         3 . The system of modular structural panels of  claim 2 , wherein the planar surface and the plurality of support members of each modular structural panel are integrally formed. 
     
     
         4 . The system of modular structural panels of  claim 3 , wherein each modular structural panel is comprised of a mix of resin and agriculture waste material. 
     
     
         5 . The system of modular structural panels of  claim 4 , wherein the mix of resin and agricultural waste material comprises a ratio of at least 50% resin to at least 20% agriculture waste material. 
     
     
         6 . The system of modular structural panels of  claim 5 , wherein the agricultural waste material is comprised of a plurality of hemp fibers. 
     
     
         7 . The system of modular structural panels of  claim 6 , wherein the plurality of hemp fibers are unidirectionally oriented across the planar surface. 
     
     
         8 . The system of modular structural panels of  claim 6 , wherein the plurality of hemp fibers are bidirectionally 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 . The system of modular structural panels of any of  claims 7 to 10 , wherein each modular structural panel is compression molded. 
     
     
         12 . The system of modular structural panels of any of  claims 7 to 10 , wherein each modular structural panel is injection molded. 
     
     
         13 . The system of modular structural panels of either of  claim 11 or 12 , wherein the plurality of tapered recesses further comprises at least one tapered recess located proximate a corner of the planar surface. 
     
     
         14 . The system of modular structural panels of any one of  claims 11 to 13 , wherein the plurality of tapered recesses further comprises at least one tapered recess located proximate an interior of the planar surface. 
     
     
         15 . The system of modular structural panels of any one of  claims 13 to 14 , wherein each support member corresponds to one tapered recess. 
     
     
         16 . The system of modular structural panels of  claim 15 , wherein each tapered recess extends through the planar surface forming a cavity within the corresponding support member. 
     
     
         17 . The system of modular structural panels of  claim 16 , further comprising at least one cover plate to enclose at least one tapered recess independent of an adjoining tapered recess, each cover plate shaped and sized to be received in each tapered recess such that when engaged the cover plate is substantially coplanar with the first plane of each modular structural panel. 
     
     
         18 . The system of modular structural panels of  claim 17 , wherein each cavity has at least one slot, each slot shaped and sized to receive one projection of each connector in an interference fit to secure two or more modular structural panels together. 
     
     
         19 . The system of modular structural panels of  claim 18 , wherein each cover plate has at least one projection shaped and sized to engage each tapered recess so as to secure the cover plate in place. 
     
     
         20 . The system of modular structural panels of  claim 19 , wherein the at least one slot of each cavity is further shaped and sized to receive one projection of each cover plate in an interference fit to secure the cover plate in place. 
     
     
         21 . The system of modular structural panels of  claim 17 , wherein each connector has at least four projections shaped and sized to engage each adjoining tapered recess so as to secure two or more modular structural panels together. 
     
     
         22 . The system of modular structural panels of  claim 21 , wherein each cavity has at least one rail extending across the cavity, each rail shaped and sized to be received between two projections of each connector in an interference fit to secure two or more modular structural panels together. 
     
     
         23 . The system of modular structural panels of  claim 22 , wherein each cover plate has at least two projections shaped and sized to engage each tapered recess so as to secure the cover plate in place. 
     
     
         24 . The system of modular structural panels of  claim 23 , wherein the at least one rail of each cavity is further shaped and sized to be received between two projections of each cover plate in an interference fit to secure the cover plate in place. 
     
     
         25 . The system of modular structural panels of either of  claim 22 or 24 , wherein each modular structural panel further comprises at least one first set of stringers extending opposite 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 being substantially perpendicular to the first set of stringers. 
     
     
         27 . The system of modular structural panels of  claim 26 , wherein the first set of stringers and the second set of stringers of each modular structural panel intersect. 
     
     
         28 . The system of modular structural panels of  claim 27 , wherein the second set of stringers comprises at least two stringers intersecting each support member, each of the stringers being substantially parallel and spaced so as to define a channel shaped and size to receive one of a plurality of structural framing members. 
     
     
         29 . The system of modular structural panels of  claim 28 , wherein each modular structural pallet is used as one or more of a pallet, a floor member, or a wall member. 
     
     
         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 ;   abutting a first edge of the first modular structural panel to a first edge of the second modular structural panel;   substantially aligning each edge support member and each corner support member along the first edge of the first modular structural panel with each edge support members and each corner support members along the first edge of the second modular structural panel forming a first plurality of adjoining tapered recesses; and   detachably connecting the first modular structural panel to the second modular structural panel along the abutting edge by inserting at least one connector in each adjoining tapered recess.   
     
     
         31 . The method of  claim 30 , further comprising covering the tapered recesses independent of the adjacent tapered recesses of each support member of the first modular structural panel and the second modular structural panel by inserting at least one cover plate in each tapered recess. 
     
     
         32 . The method of  claim 31 , further comprising slidably engaging at least one projection of the connector in the at least one slot in the cavity of each aligned support member along the abutting edge 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 projection of the cover plate in the at least one slot in the cavity of each support member, other than the support members along the abutting edge, to secure each cover plate in place. 
     
     
         34 . The method of  claim 31 , further comprising slidably engaging the at least one rail in the cavity of each aligned support member along the abutting edge between at least two projections 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 rail in the cavity of each support member, other than the support members along the abutting edge, between at least two projections to secure each cover plate in place. 
     
     
         36 . The method of either of  claim 33 or 35 , further comprising at least one additional modular structural panel, and the method further comprises: repeating the method defined in  claims 33 to 35 , for each additional 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 orienting the system of modular structural panels vertically for use as a wall. 
     
     
         39 . The method of either  claim 37 or 38 , further comprising inserting the plurality of structural framing 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 a floor and orienting a second system of modular structural panels vertically for use as a wall, connecting the first system of modular structural panels to the second system of modular structural panels using a plurality of 90-degree connectors inserted in the adjoining tapered recesses of adjacent support members.