Molded panel, molded panel system and connection system

Abstract

A molded panel is provided, which includes a body and a plurality of supporting members. The body includes a generally planar top surface and a bottom surface. The supporting members extend from the bottom surface of the body to define a support structure. The support structure includes a top surface adjacent to the bottom surface of the body, a generally planar bottom surface and at least one edge extending therebetween. The support structure also includes at least one channel extending along a central x-axis of the support structure, and at least one additional channel intersecting the at least one central channel and extending along a y-axis of the support. The y-axis is generally perpendicular to the x-axis. A connection system for the molded panel, systems including the molded panel, and methods related to the molded panel are also described.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a molded panel in accordance with the present invention;

FIG. 2 is a bottom plan view of the molded panel of FIG. 1;

FIG. 3 is a cross-sectional view of the molded panel of FIG. 2, taken along lines 3-3 of FIG. 2;

FIG. 4 is a cross-sectional view of the molded panel of FIG. 2, taken along lines 4-4 of FIG. 2

FIG. 5 is a top plan view of a portion of a panel in accordance with the present invention showing notches in the sides of the panel for receiving a connecting member and a receiving member;

FIG. 6 is a bottom plan view of the panel portion of FIG. 5;

FIG. 7A is a side elevational view of a portion of a panel according to the present invention showing a notch for receiving the connecting member;

FIG. 7B is a perspective view of a portion of the panel of FIG. 7A;

FIG. 8A is a side elevational view of a portion of a panel according to the present invention showing a notch for receiving the receiving member;

FIG. 8B is a perspective view of a portion of the panel of FIG. 8A;

FIG. 9 is an exploded perspective view of a connecting member and a receiving member of a connecting system according to the present invention, some but not all of the components and elements of the connection system are depicted in relative alignment with each other in FIG. 9;

FIG. 10 is an assembled perspective view of the connecting member and the receiving member of FIG. 9;

FIG. 11 is a side elevational view of a portion of the panel of FIG. 1 showing a connecting member;

FIG. 12 is a side elevational view of a portion of the panel of FIG. 1 showing a receiving member;

FIG. 13 is a top plan view showing two connected panels in accordance with the present invention;

FIG. 14 is a top plan view showing a connecting member fastened to a receiving member according to the present invention;

FIG. 15 is a bottom plan view of the connecting member and receiving member of FIG. 14;

FIG. 16 is a cross-sectional view of two connected panels supported by a floor support surface according to the present invention;

FIG. 17 is a cross-sectional view of two connected panels supported by a wall support surface according to the present invention;

FIG. 18 is a top plan view of a molding system used to mold a panel in accordance with the present invention;

FIG. 19 is a side elevation view of the molding apparatus of FIG. 18;

FIGS. 20A-20E are plan views of the mold of the molding system of FIGS. 18 and 19 in different steps of the process of molding a panel in accordance with the present invention;

FIG. 21 is a side elevation of an extruder of the molding system of FIGS. 18 and 19;

FIG. 22 is a rear elevation of the extruder of FIG. 21;

FIG. 23 is an exemplary schematic diagram of an extrusion-molding system operable to form a molded panel in accordance with the present invention;

FIG. 24 is another exemplary block diagram of the extrusion-molding system of FIG. 23;

FIG. 25 is an exemplary exploded view of a dynamic die of the extrusion-molding system of FIG. 23 depositing extruded thermoplastic material on a lower mold as supported by a trolley;

FIG. 26 is an exemplary flow diagram illustrating the extrusion-molding process utilized to form a panel by using either two- or three-axis control for depositing the thermoplastic material onto the lower mold of FIG. 23;

FIG. 27 is another exemplary flow diagram illustrating the extrusion-molding process utilized to form a panel by using the three-axis control for depositing the thermoplastic material onto the lower mold of FIG. 23;

FIG. 28 is an exemplary block diagram of a controller interfacing with controllers operating in components of the extrusion-molding system of FIG. 23;

FIG. 29 is a more detailed exemplary block diagram of the controller of FIG. 28;

FIG. 30 is an exemplary block diagram of the software that is executed by a processor operating the controller of FIGS. 28 and 29;

FIG. 31 is an exemplary schematic of the flow control elements and a lower mold, which is sectioned into a grid, to deposit extruded thermoplastic material in accordance with the extrusion-molding system of FIG. 23;

FIG. 32 is a top view of the flow control elements as aligned to deposit the thermoplastic material onto the lower mold of FIG. 23;

FIG. 33 is a representative flow diagram describing the operations for embedding an insert, such as a connecting system, support or other element into a structural part utilizing the extrusion-molding system of FIG. 23;

FIG. 34 is a representative exploded perspective view of an arrangement, in accordance with an embodiment of the present invention, of the plates of the connecting member and the receiving member, in which molded panels are not depicted for purposes of improved clarity and illustration;

FIG. 35 is a representative exploded perspective view of an arrangement of the plates of the connecting member and the receiving member, similar to that depicted in FIG. 34 but in which the second plate of the connecting member is repositioned; and

FIG. 36 is a representative exploded perspective view of a connection system fastener assembly.

Claims

1. A molded panel comprising: a) a body comprising: (i) a generally planar top surface; and(ii) a bottom surface; andb) a plurality of supporting members extending from the bottom surface of the body to define a support structure comprising a top surface adjacent to the bottom surface of the body, a generally planar bottom surface and at least one edge extending therebetween, at least one central channel extending along a central x-axis of the support structure from a first portion of the edge to a second, opposing portion of the edge along the x-axis, and at least one additional channel intersecting at least one central channel and extending along a y-axis of the support structure from a third portion of the edge to a fourth, opposing portion of the edge along the y-axis, the y-axis being generally perpendicular to the x-axis.

2. The molded panel of claim 1 wherein a mean average thickness of the support structure between an apex of the central channel and the top surface of the support structure is less than a mean average thickness of at least one support member between the top surface and bottom surface of the support structure.

3. The molded panel of claim 2 wherein the mean average thickness of the support structure between said apex of the central channel and the top surface of the support structure is about 0.6 cm (0.25 inch) to about 1.3 cm (0.5 inch).

4. The molded panel of claim 2 wherein the mean average thickness of the at least one support member between the top surface and bottom surface of the support structure is about 1.9 cm (0.75 inches) to about 6.4 cm (2.5 inches).

5. The molded panel of claim 1 wherein, an average cross-sectional area of a portion of a plane within the support structure defined between the central channel and the top surface of the support structure at a maximum width of the central channel,is less than,an average cross-sectional area of a portion of a plane of at least one support member defined between the top surface and the bottom surface of the support structure and having a width equal to the maximum width of the central channel.

6. The molded panel of claim 5 wherein the average cross-sectional area of said portion of said plane within the support structure defined between the central channel and the top surface of the support structure is about 0.7 cm2 (0.1 in2) to about 3.2 cm2 (0.5 in2).

7. The molded panel of claim 5 wherein the average cross-sectional area of said portion of said plane of at least one support member defined between the top surface and the bottom surface of the support structure and having said width equal to the maximum width of the central channel is about 2 cm2 (0.3 in2) to about 16.1 cm2 (2.5 in2).

8. The molded panel of claim 1 wherein an overall dimension of the molded panel is about 122 cm (4 ft) by about 244 cm (8 ft).

9. The molded panel of claim 1 wherein the molded panel has a warpage of less than about 5%.

10. The molded panel of claim 1 wherein the plurality of supporting members are formed as a plurality of ribs together defining a pattern of void spaces therebetween.

11. The molded panel of claim 10 wherein said pattern is selected from the group consisting of squares, rectangles, pentagons, hexagons, octagons, triangles, circles and combinations thereof.

12. The molded panel of claim 10 wherein the plurality of supporting members are formed as a plurality of ribs forming a pattern of generally squares to define the void spaces therebetween.

13. The molded panel of claim 10 wherein the plurality of ribs each have a thickness of about 1.9 cm (0.75 inch) to about 6.4 cm (2.5 inches).

14. The molded panel of claim 10 wherein the plurality of ribs each have a width of about 1.0 cm (0.4 inch) to about 2.5 cm (1 inch).

15. The molded panel of claim 10 wherein each rib is spaced apart from a neighboring rib by about 2.0 cm (0.8 inch) cm to about 7.6 cm (3 inches).

16. The molded panel of claim 10 wherein said central channel and each additional channel are each formed during a molding process by molding the pattern of the plurality of ribs in the absence of at least one rib extending along the central x-axis of the support structure from the first portion of the edge to the second, opposing portion of the edge along the x-axis, and in the absence of at least one rib extending along the y-axis of the support structure from the third portion of the edge to the fourth, opposing portion of the edge along the y-axis.

17. The molded panel of claim 1 further comprising a system for interconnecting the molded panel with a second molded panel.

18. The molded panel of claim 17 further comprising a plurality of notches positioned along the body of the molded panel adapted to receive the system for interconnecting the molded panel with the second molded panel.

19. The molded panel of claim 18 wherein the system for interconnecting the molded panel with the second molded panel comprises a connecting member adapted to interconnect with a receiving member.

20. The molded panel of claim 1 wherein the molded panel is formed from a material selected from the group consisting of thermoplastic materials, thermosettable materials and combinations thereof.

21. The molded panel of claim 1 wherein the molded panel is formed from a material that is reinforced with fibers.

22. The molded panel of claim 1 wherein the molded panel is a floor panel for covering a support surface.

23. The molded panel of claim 22 wherein the support surface is selected from the group consisting of concrete, ice, earth, wood, grass, metal, studs and combinations thereof.

24. The molded panel of claim 1 wherein the molded panel is a wall panel for covering a support surface.

25. The molded panel of claim 24 wherein the support surface is selected from the group consisting of drywall, studs, brick, wood, metal and combinations thereof.

26. A connection system comprising: a) a connecting member comprising: (i) a first plate having a hole proximate a first end of the first plate;(ii) a support plate positioned generally parallel to the first plate and having a first hole located in a central region of the support plate such that the first hole is generally aligned with the hole of the first plate, and a second hole spaced apart from the first hole proximate a first end of the support plate; and(iii) a top plate positioned generally parallel to the support plate and having (1) a first hole located in a central region of the top plate such that the first hole of the top plate is generally aligned with the first hole of the support plate and the hole of the first plate, and (2) a second hole spaced apart from the first hole of the top plate proximate a first end of the top plate and generally aligned with the second hole of the support plate; andb) a receiving member comprising: i) a first plate having a hole located in a central region thereof; andii) a second plate positioned generally planar to but spaced apart from the first plate, the second plate having a slot extending from a first end of the second plate into a central region of the second plate such that at least a portion of the slot in the central region of the second plate is generally aligned with the hole in the central region of the first plate; andc) at least one connection system fastening member for connecting the connecting member and the receiving member together, thereby inhibiting relative movement between said connecting member and said receiving member,wherein a portion of the support plate of the connecting member is positioned between the first plate and the second plate of the receiving member such that the second hole of the support plate and the second hole of the top plate of the connecting member are aligned with the hole of the first plate of the receiving member and a portion of the slot of the second plate of the receiving member in the central region of the second plate of the receiving member, thereby allowing the connection system fastening member to be inserted through,the second hole of said top plate of said connecting member,a portion of the slot of said second plate of said receiving member,the second hole of said support plate of said connecting member, andthe hole of said first plate of said receiving member, so as to inhibit relative movement of the connecting member and the receiving member in a plane generally parallel to,the top plate, the support plate and the first plate of said connecting member, andthe second plate and the first plate of said receiving member.

27. The connection system of claim 26 wherein the connection system is disposed within a portion of a panel system comprising a first molded panel and a second molded panel, said first molded panel comprising at least one receiving member, and said second molded panel comprising at least one connection member, said connection system fixedly attaching at least a portion of said first molded panel to at least a portion of said second molded panel.

28. The connection system of claim 26 wherein the connecting member further comprises: (iv) a second plate positioned generally planar and adjacent to the first plate of said connecting member and being spaced from said top plate of said connecting member, the second plate comprising an elongated slot along a longitudinal axis in a central region thereof, further wherein, a portion of said support plate of said connecting member is interposed between said top plate of said connecting member and said second plate of said connecting member.

29. The connection system of claim 26 wherein the connecting member further comprises: (iv) a second plate positioned generally planar and adjacent to said top plate of said connecting member and being spaced from the first plate of said connecting member, such that a portion of said support plate is positioned between the first plate of said connecting member and the second plate of said connecting member, the second plate of said connecting member comprising an elongated slot along a longitudinal axis in a central region thereof.

30. The connection system of claim 26 wherein said support plate of said connecting member has a thickness, said top plate of said connecting member has a thickness, said first plate of said connecting member has a thickness, and said top plate and said first plate of said connecting member have a combined thickness, further wherein said thickness of said support plate of said connecting member is greater than said combined thickness of said first plate and said top plate of said connecting member.

31. The connection system of claim 26 wherein each connection system fastening member is independently selected from the group consisting of bolt and nut combinations, screws, pins and combinations thereof.

32. A panel system comprising: a) at least two molded panels, each panel comprising: (i) a body comprising: (1) a generally planar top surface; and(2) a bottom surface; and(ii) a plurality of supporting members extending from the bottom surface of the body to define a support structure comprising a top surface adjacent to the bottom surface of the body, a generally planar bottom surface and at least one edge extending therebetween, at least one central channel extending along a central x-axis of the support structure from a first portion of the edge to a second, opposing portion of the edge along the x-axis, and at least one additional channel intersecting the at least one central channel and extending along a y-axis of the panel from a third portion of the edge to a fourth, opposing portion of the edge along the y-axis, the y-axis being generally perpendicular to the x-axis,b) a connection system disposed within a portion of each of the at least two panels,wherein the at least two panels are interconnected by the connection system.

33. The panel system of claim 32 wherein the connection system comprises: a) a connecting member comprising: (i) a first plate having a hole proximate a first end of the first plate;(ii) a support plate positioned generally parallel to the first plate and having a first hole located in a central region of the support plate such that the first hole is generally aligned with the hole of the first plate, and a second hole spaced apart from the first hole proximate a first end of the support plate; and(iii) a top plate positioned generally parallel to the support plate and having (1) a first hole located in a central region of the top plate such that the first hole of the top plate is generally aligned with the first hole of the support plate and the hole of the first plate, and (2) a second hole spaced apart from the first hole of the top plate proximate a first end of the top plate and generally aligned with the second hole of the support plate; andb) a receiving member comprising: i) a first plate having a hole located in a central region thereof; andii) a second plate positioned generally planar to but spaced apart from the first plate, the second plate having a slot extending from a first end of the second plate into a central region of the second plate such that at least a portion of the slot in the central region of the second plate is generally aligned with the hole in the central region of the first plate; andc) at least one connection system fastening member for connecting the connecting member and the receiving member together, thereby inhibiting relative movement between said connecting member and said receiving member,wherein a portion of the support plate of the connecting member is positioned between the first plate and the second plate of the receiving member such that the second hole of the support plate and the second hole of the top plate of the connecting member are aligned with the hole of the first plate of the receiving member and a portion of the slot of the second plate of the receiving member in the central region of the second plate of the receiving member, thereby allowing the connection system fastening member to be inserted through,the second hole of said top plate of said connecting member,a portion of the slot of said second plate of said receiving member,the second hole of said support plate of said connecting member, andthe hole of said first plate of said receiving member, so as to inhibit relative movement of the connecting member and the receiving member in a plane generally parallel to,the top plate, the support plate and the first plate of said connecting member, andthe second plate and the first plate of said receiving member.

34. The panel system of claim 32 wherein the at least two panels are floor panels for covering a floor support surface.

35. The panel system of claim 34 wherein the floor support surface is selected from the group consisting of concrete, ice, earth, wood, grass, metal, studs and combinations thereof.

36. The panel system of claim 32 wherein the at least two panels are wall panels for covering a wall support surface.

37. The panel system of claim 36 wherein the wall support surface is selected from the group consisting of dry wall, studs, brick, wood, metal and combinations thereof.

38. A molded panel comprising: a body comprising a generally planar top surface and a bottom surface; and a plurality of supporting members extending from the bottom surface of the body to define a support structure comprising a top surface adjacent to the bottom surface of the body, a generally planar bottom surface and at least one edge extending therebetween, the support structure having at least one central channel extending along a central x-axis of the support structure from a first portion of the edge to a second, opposing portion of the edge along the x-axis, and at least one additional channel intersecting the at least one central channel and extending along a y-axis of the panel from a third portion of the edge to a fourth, opposing portion of the edge along the y-axis, the y-axis being generally perpendicular to the x-axis, wherein the molded panel is prepared by a process comprising the steps of:a) feeding a molten thermoplastic material into a mold adapted to form the molded panel; andb) applying pressure to the molten thermoplastic material to form the molded panel.

39. The molded panel of claim 38 wherein the process for preparing the molded panel further comprises heating feed thermoplastic material to form said molten thermoplastic material before feeding the molten thermoplastic material into said mold.

40. The molded panel of claim 38 wherein the mold comprises an upper mold portion and a lower mold portion.

41. The molded panel of claim 40 wherein the step of feeding said molten thermoplastic material into said mold comprises: (i) extruding feed molten thermoplastic material to form said flow of molten thermoplastic material;(ii) gravitating said flow of molten thermoplastic material onto the lower mold portion; and(iii) moving the lower mold portion in space and time while the flow of molten thermoplastic material is received in said lower mold portion, so as to deposit a predetermined quantity of molten thermoplastic material in the lower mold portion.

42. The molded panel of claim 41 wherein the step of applying pressure to the molten thermoplastic material comprises pressing the upper mold portion against the predetermined quantity of molten thermoplastic material received in said lower mold portion.

43. The molded panel of claim 41 wherein the step of extruding the molten thermoplastic material to form said flow of molten thermoplastic material further comprises controlling the flow of molten thermoplastic material so as to vary the predetermined quantity of molten thermoplastic material being deposited in the lower mold portion.

44. A process for preparing a molded panel comprising the steps of: a) feeding a molten thermoplastic material into a mold adapted to form the molded panel; andb) applying pressure to the molten thermoplastic material to form the molded panel,wherein the panel comprises a body comprising a generally planar top surface and a bottom surface; and a plurality of supporting members extending from the bottom surface of the body to define a support structure comprising a top surface adjacent to the bottom surface of the body, a generally planar bottom surface and at least one edge extending therebetween, the support structure having at least one central channel extending along a central x-axis of the support structure from a first portion of the edge to a second, opposing portion of the edge along the x-axis, and at least one additional channel intersecting the at least one central channel and extending along a y-axis of the panel from a third portion of the edge to a fourth, opposing portion of the edge along the y-axis, the y-axis being generally perpendicular to the x-axis.

45. The process of claim 44 further comprising heating feed thermoplastic material to form said molten thermoplastic material before feeding the molten thermoplastic material into said mold.

46. The process of claim 44 wherein the mold comprises an upper mold portion and a lower mold portion.

47. The process of claim 46 wherein the step of feeding said molten thermoplastic material into said mold comprises: (i) extruding feed molten thermoplastic material to form said flow of molten thermoplastic material;(ii) gravitating said flow of molten thermoplastic material onto the lower mold portion; and(iii) moving the lower mold portion in space and time while the flow of molten thermoplastic material is received in said lower mold portion, so as to deposit a predetermined quantity of molten thermoplastic material in the lower mold portion.

48. The process of claim 47 wherein the step applying pressure to the molten thermoplastic material comprises pressing the upper mold portion against the predetermined quantity of molten thermoplastic material received in said lower mold portion.

49. The process of claim 47 wherein the step of extruding the molten thermoplastic material to form said flow of molten thermoplastic material further comprises controlling the flow of molten thermoplastic material so as to vary the predetermined quantity of molten thermoplastic material being deposited in the lower mold portion.

50. A method of connecting molded panels comprising the steps of: a) providing at least a first molded panel and a second molded panel, each molded panel comprising a body comprising a generally planar top surface and a bottom surface; and a plurality of supporting members extending from the bottom surface of the body to define a support structure comprising a top surface adjacent to the bottom surface of the body, a generally planar bottom surface and at least one edge extending therebetween, the support structure having at least one central channel extending along a central x-axis of the support structure from a first portion of the edge to a second, opposing portion of the edge along the x-axis, and at least one additional channel intersecting the at least one central channel and extending along a y-axis of the panel from a third portion of the edge to a fourth, opposing portion of the edge along the y-axis, the y-axis being generally perpendicular to the x-axis,wherein said first molded panel further comprises at least one connecting member, and said second molded panel further comprises at least one receiving member;b) aligning at least one connecting member and at least one receiving member such that a portion of a support plate of the connecting member is positioned between a first plate and a second plate of the receiving member such that a second hole of said support plate and a second hole of a top plate of the connecting member are aligned with a hole of the first plate of the receiving member and a portion of a slot of the second plate of the receiving member in a central region of the second plate of the receiving member; andc) inserting a connection system fastening member through,the second hole of said top plate of said connecting member,said portion of the slot of said second plate of said receiving member,the second hole of said support plate of said connecting member, andthe hole of said first plate of said receiving member, so as to inhibit relative movement of the connecting member and the receiving member in a plane generally parallel to,the top plate, the support plate and the first plate of said connecting member, andthe second plate and the first plate of said receiving member.