Field of the Invention

The present invention relates to a modular construction panel and system that are particularly applicable for use with rapid deployment, semi-permanent and permanent structures.

Background to the Invention

While conventional building materials are well suited for conventional applications such as domestic and commercial construction where the materials are available locally to the building project, they are generally not well suited to situations where the materials must be transported long distances to the building site, often in inhospitable environments. For example, you would not normally consider using conventional building materials to construct a tent because the general premise is that a tent can be disassembled and moved with limited physical assistance when necessary. Disassembling a bricks and mortar building is difficult enough - even if the materials could then be transported to another site, subsequent reassembly is generally not possible due to the damage done to the materials during disassembly. The idea of tents and similar shelters is that they can be thrown up at a moments notice (and disassembled at a similar speed). The preparation and care needed for construction using more conventional building materials is not desirable for temporary shelters such tents, even if the rigidity and weather proofing provided by such conventional materials is desired.

This situation arises frequently in military maneuvers, exploration and also in humanitarian aid projects. There is a desire for low cost, lightweight construction systems that are easily transported, simple to assemble and provide shelter from the outside environment. A further desire in such situations is for that of heating and electrical power. These are generally unavailable due to the remote locations and

unwillingness to transport generators around. Even where generators and heaters are available, they must be used sparingly to conserve what little fuel is normally available to the generator/heater. There have been some attempts to produce portable solar energy collectors but these have met with only limited success due to the need for mounting them on a rigid support. Transporting a dedicated support mast or the like is often not feasible and mounting on available structures such as tents is generally not possible due to the substantial weight of the solar collectors.

Most solar collectors are of the flat plate collector type or evacuated tube type. Flat plate collectors generally have glass surfaces, evacuated tubes are also typically glass and both types are therefore prone to breaking during

transportation and assembly/installation. They are designed to be transported carefully, fitted once and left on a roof. The flat plate collectors are large and are usually fitted on a roof using lifting equipment. They are therefore not suitable to be disassembled and transported to a new site. Flat plate collectors are typically very heavy due to their materials and construction methods. Their frames are usually extruded aluminum and their front face is glass. This makes them difficult to transport and instal as well as expensive. There are already light weight, low cost solar collectors available. One type is a twin wall inflatable solar collector, manufactured from thin sheet polymer. These are prone to puncture and bursting. They also have limited insulation as it relies simply on air pockets. The system is also difficult to structurally integrate and therefore has limited use.

Other solar collectors have been integrated into standard sized roof tiles.

Again, such products are intended to be fitted once and left. They also require careful transportation and handling as they have a glass cover making the unit heavy and fragile.

Statement of Invention

According to an aspect of the present invention, there is provided a modular construction panel formed from a material which includes a multitude of rubber particles, the panel including interconnection means for

interconnecting with another panel, wherein the interconnection means is arranged, when two panels are interconnected, to resist movement of the two panels with respect to each other and thereby form a substantially rigid structure.

The interconnection means may include one or more clamps or screw threads arranged to mate with a corresponding interconnection means of another panel or structure. The interconnection means may be embedded or formed within the modular panel.

Preferably, one or more of the modular panels comprises a solar collector panel which includes a solar collector. The solar collector may be integrated or installed/affixed to the modular panel. The solar collector panel includes one or more circuit connectors for connecting a solar energy collection circuit to adjacent modular panels. Non-solar collector panels may also include one or more circuit connectors for bridging the solar energy collection circuit between solar collector panels that are adjacent to the non-solar collector panel. The solar collector may be a solar thermal panel or a solar voltaic panel. The or each circuit connector may comprise a pipe coupleable to a pipe of the one or more adjacent modular panels. The or each circuit connector may include a push fit connector arranged to releasably connect to a corresponding connector on an adjacent panel. The or each circuit connector may include a plumbing or electrical connector for connecting a respective liquid or electrical circuit between adjacent panels. The modular panel is preferably formed from a multitude of rubber particles bound by a binding agent. Each rubber particle may be a rubber crumb such as recycled rubber tyre material. Each rubber crumb may be approximately 150 micro metres to 5mm in diameter. The binding agent may include a thermoplastic. The ratio by weight of rubber particles to binding agent may be about 3:1 .

The modular construction panel may further comprise one or more types of additive particles mixed with the rubber particles and bound by the binding agent. The additive particle types may include, amongst others, one or more of the following in particulate form: brick; concrete; glass; carbon fibre and/or glass fibre.

The panel may be compression or injection moulded, although it could also be formed in other ways.

The modular construction panel may further comprise an externally facing surface, at least a part of said externally facing surface being arranged to be solar selective.

The modular construction panel may optionally further comprise a fluid channel for accommodating a heat transfer fluid.

According to another aspect of the present invention, there is provided a modular construction system comprising a frame and a plurality of modular construction panels as discussed above, the frame defining a skeleton of a structure, the modular construction panels being connectable to each other and to the frame to form one or more surfaces of the structure. One or more of the plurality of modular construction panels may comprise a solar collector arranged to generate heat and/or electricity, the modular construction system including an outlet for connection to said solar collector for obtaining said generated heat and/or electricity.

Embodiments of the present invention seek to address the main issues of the prior art by providing a low cost, light weight modular system that is

manufactured from rugged materials that enable ease of transportation (even being air dropped to point of use) and simple to assemble and operate. In preferred embodiments, the system incorporates an integrated solar collector which enables integration or mounting to permanent or semi-permanent structures such as tents and shelters and provides hot water and/or power whilst reducing the solar gain inside the structure.

Particular advantages of the system are: · Low Cost - The modular panels are preferably manufactured from low cost materials.

• Light Weight - The individual modular panels are manufactured from lightweight materials. Due to their size and manufacturing methods there is not the requirement for heavy metal structures as in

conventional panels.

• Small Modular Size - The individual modular panels are small and because they are modular, they can be light weight and portable. They can be connected into multiple combinations enabling unique system designs and layouts.

· Rugged and Durable -The design and material selection preferably used results in the modular panels being very strong, rugged and durable. This enables the panels to be used in harsh and difficult environments such as war and disaster zones.

• Easy to transport - As the panels are modular, lightweight and rugged, they are very easy and cost effective to transport. The design and materials lend themselves to being crated up and air-dropped to wherever they need to be used.

Easy to handle and assemble - The modular panels are light weight and small enough to be handled by people without the aid of lifting equipment. The panels join together using simple fittings that enable them to be fitted very quickly and easily. The fittings are also selected for ease of disassembly which allows the system to be quickly disassembled and moved to another location if required.

Construction Materials - The system can be integrated into structures such as walls and roofs to provide structural integrity and forgo the requirement of additional materials to create rapid shelters and structures.

Panels can be integrated into a structure such as a tent frame to create walls and roof surfaces that, in preferred embodiments, capture the solar energy and use it to heat liquids or generate power. This process prevents the enclosed structure from becoming excessively warm through solar gain in hot environments. The modular design allows assembly and disassembly of the solar system to enable the system to be reused in different locations. The materials, manufacturing and construction processes enable a rugged modular product ideal for military and humanitarian aid situations by its ability to be air-dropped. Solar collector panels can include a solar selective material such as Tinox® but could also be used with out.

The solar collector panels preferably connect together using simple push fit connectors that have the ability to be taken apart again such as push fit plumbing or electrical connectors to allow a water circulation circuit or electrical circuit between the panels to be created for energy collection. In the case of water, the connectors may, for example, be of the Festo Mini Series Push-In Fitting type.

The Modular panels are connected and fixed together into larger panels, such as (but not limited to) 1 m ² sized panels which may then be attached to other panels or integrated into a structure or frame. At least some of the panels may be solar collector panels which would then connected together by use of pipes and manifolds to enable an efficient solar system to be created.

· The panels can be mounted on or integrated into external structures or frames through the use of fixings such as screws, bolts and brackets.

Brief Description of the Drawings

Embodiments of the present invention will now be described in detail by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a perspective view of a modular construction panel according to an embodiment of the present invention;

Figure 2 is a perspective view of a structure formed from panels of Figure 1 according to an embodiment of the present invention; Figure 2a is a sectional view of an edge profile of the panel of Figure 2;

Figures 3a-3c are perspective views of interconnection means of Figure 1 ; Figures 4a-4f are perspective views of a tent structure assembled from the structures of Figure 2 according to an embodiment of the present invention; and,

Figures 5, 6, 7a and 7b are perspective views of a modular construction panel and a structure according to preferred embodiments of the present invention;

Detailed Description

Figure 1 is a perspective view of a modular construction panel according to an embodiment of the present invention.

The modular construction panel 10 is formed from a material which includes a multitude of rubber particles. Preferably, the rubber particles comprise a rubber crumb material. Most preferably, the source of the rubber crumb is recycled tyres. The rubber particle based panel is advantageous in this use because it is able to absorb significant amounts more heat than a standard plastics based body without significantly affecting the structural integrity of the panel. Additionally, the material is cheap, lightweight and formed from predominantly recycled materials.

As the rubber cannot be melted, the crumb is preferably bound together using a binding agent to give the necessary physical properties needed for the panel.

The binding agent may be a thermoplastic material (referred to as the

"matrix"). The distribution of particles in the matrix is preferably uniform as this is desirable where uniform energy absorption and structural integrity is required. However, non uniform distribution may be beneficial in some cases where the differing physical properties of the matrix and rubber particles could be harnessed advantageously to provide additional features relating to functionality or strength.

Further additives may be included within the rubber-matrix mixture. These may include:

Recycled brick dust

Recycled Concrete

Recycled Glass bottles

Recycled Carbon Fibre

Recycled Glass Fibre

Additives such as these provide increases in properties such as: strength under tension and compression; density and mass; increased strength;

increased thermal adsorption; and, increased thermal mass.

It will be appreciated that the additives (and indeed the rubber particles) need not be recycled materials but of course use of the recycled materials results in material saving and a significant reduction on environmental impact by production of the panels.

The structural and thermal properties of the panel can be altered by changing the ratios of rubber crumb and binder.

Preferably, the binding agent includes polypropylene and/or polyethylene, although it will be appreciated that other thermoplastics or other binding agents could be used either alone or in combination. The binding agent selected needs good functionality with the rubber and good heat stability.

The panel 10 is preferably formed by a pressure moulding process such as compression moulding or injection moulding. Preferably, injection moulding is used.

In the case of compression moulding, the thermoplastic material would be mixed with the rubber particles and heated prior to moulding. A discrete shot of material is weighed out and then compressed in a mould. In a pressure moulding process where melting the thermoplastic may be difficult, a more conventional adhesive binder could be used.

Preferably the ratio by weight of rubber tyre crumb to thermoplastic is approximately 3:1 . It will be appreciated that the exact ratio will depend on many factors such as cost, particle size of the crumb, binding agent, intended environment of use, and design of the panel. Ratios of 10:1 or even 20:1 up to 1 :1 are possible.

Rubber tyre crumb particles of approximately 150micro metres to 5mm in diameter are preferred although this is not essential. Lesser or greater approximate particle diameter (as it will be appreciated that the particles may not be of a uniform or regular shape) could be used. The panel includes interconnection means 20 (in this embodiment formed from projections 60 and screw holes 50 that can be abutted and then clamped together by screwing a bolt through the screw holes) for interconnecting with another panel. The interconnection means 20 is arranged, when two or more of the panels are interconnected, to resist movement of the panels with respect to each other and thereby form a substantially rigid structure, as is shown in Figure 2. It will be appreciated that some of the panels illustrated in the following Figures are square and some rectangular. While same-sized panels throughout is preferred from a simplicity of manufacturing and installation point of view, as long as the interconnection means will meet at the correct points, there is no reason why different geometry panels could not be mixed together. Figure 2a is a sectional view of an edge profile of the panel of Figure 2. The edge of the panel may, as illustrated include a locking profile that interlocks with an adjacent panel to help location and locking of panels and channel away rainwater and the like falling on the structure. It will be appreciated that the interconnection means may take many forms. Preferably, the interconnection means clamps two adjacent panels together when their sides are abutting to create the substantially rigid structure. The panels may have a threaded feature moulded into them in thermoplastic or a pre-threaded metal (such as brass) insert could be insert moulded to enable the panels to be locked together.

The interconnection means is preferably arranged to enable interconnection with external structures such as a frame of a structure such as a tent. Figure 3a illustrates one possible arrangement for the interconnection means. The interconnection means in this embodiment comprises a threaded nut 50 formed (or inserted during moulding) in a projection 60 in each modular panel 10. During assembly, the projections 50 are overlapped and a threaded bolt 70 is inserted to secure the two panels together. As shown in Figure 3b, a tube clamp 80 may also be provided which enables modular panel(s) 10 to be secured to supporting posts/frames such as those of tents or other sub- structures as shown in Figure 3c. This assembly is further illustrated in Figure 4a-4f in which panels are assembled together in groups of 4 and then attached to a supporting tent structure 90.

Figure 5 is a perspective view of a modular construction panel according to a preferred embodiment of the present invention;

In preferred embodiments of the present invention, a number of different panel types are available, the different panel types each having the

interconnection means discussed in Figures 1 to 4 to enable the modular panels to interconnect with other panels of the same type or with modular panels of differing types.

The panel types may include:

a basic panel as discussed with reference to Figure 1 ;

a solar collector panel incorporating a solar collector in the form of a solar thermal panel; and,

a solar collector panel incorporating a solar collector in the form of a solar voltaic panel. In the case of solar thermal and solar voltaic panels, there are collectively referred to as solar collector panels and are discussed below.

Three solar collector panels are shown in Figure 6 (with a non solar collector panel bridged between them). Each solar collector panel includes a solar collector 100 incorporated within a modular panel 10 to form an integral panel. The solar collector 100 may be manufactured separately and then affixed or installed within a modular panel 10 or alternatively at least components of the solar collector 100 may be formed during formation of the modular panel 10.

Solar collectors 100 either produce heated water or electricity depending on their type. In each case, an appropriate circuit connector 1 10 is provided within the modular panel 10 to allow passage of water or flow of generated current out of the modular panel 10.

In the case of a solar collector being a solar thermal panel, the modular panel may include a fluid channel which accommodates air, water or some other heat transfer fluid. The fluid channel could be formed as part of the rubber particle-matrix mix or it could be a pre-made structure embedded into the rubber particle-matrix mix. In a typical arrangement, the fluid would be pumped or otherwise driven around the fluid circulation circuit. As the fluid passes through the channel or channels, it absorbs heat from both solar rays and from that previously absorbed by the matrix. At some point in the circuit, the fluid passes through a heat exchanger and the absorbed heat is extracted (for use in heating etc). The circuit connector may be positioned at the sides (as shown in Figure 7a) or on the back face (as shown in Figure 7b) of each modular panel . The circuit connector end may be barbed for retaining in place in the panel.

Preferably, modular panels incorporating solar thermal panels have push fit plumbing type circuit connectors that interconnect corresponding circuit connectors of an adjacent modular panel when the panels are interconnected (or allow connection to an external fluid circuit). This connection would be in addition to the interconnection means described above with reference to Figure 1 which provides structural integrity. Modular panels incorporating solar voltaic panels would include electrical circuit connectors to connect to adjacent modular panels (or allow connection to an external unit). As illustrated in Figure 6 by dotted lines, the circuit passes through the solar collectors and also through the modular panel to connect to the adjacent modular panel. Of course, connection is only possible if an appropriate circuit connector is present on the adjacent modular panel. In some embodiments, only a modular panel of the same type will have the same circuit connector. In other embodiments, such as that illustrated in Figure 6 all modular panels may have all circuit connector types. For example, it would be possible to embed pipes or electrical wiring within basic panels so that solar collector panels could be joined to form a circuit even if they are not adjacent.

The modular solar collector panels may optionally be covered with a solar absorbing sheet such as Tinox(RTM). An Ultra Violet (UV) stabilising layer such as transparent Polymethyl Methacrylate (PMMA) or Polycarbonate with a UV absorbent top layer may also be placed over the panel. Preferably, this will contain additives to prevent environmental attack and degradation to weathering protection and thermal insulation. The sheet will also preferably be treated to be self cleaning and prevent growth such as algae.

The solar radiation absorption sheet is preferably inserted in the injection mould tool prior to injection of the rubber filler thermoplastic and over moulded using in-mould lamination techniques to give adherence to the base layer.

In the case of a modular panel which includes an integral solar thermal panel, a plurality of fluid flow channels are formed in the panel the panel may then optionally be covered with a solar absorbing sheet such as Tinox® and an Ultra Violet (UV) light absorbing transparent Polymethyl Methacrylate (PMMA) or Polycarbonate with a UV absorbent top layer is then preferably placed over the panel. Preferably, this will contain additives to prevent environmental attack and degradation to weathering protection and thermal insulation. The sheet will also preferably be treated to be self cleaning and prevent growth such as algae. Subject to optimal selection of the thermoplastic base, the solar absorbing sheet may not be necessary. For example, it has been found that a rubber tyre crumb filled thermoplastic matrix, preferably which is black, absorbs a significant amount of heat such that the solar absorbing sheet is unnecessary.

Solar collector panel manufacture:

• The base layer will preferably be injection moulded using a rubber tyre crumb filled thermoplastic matrix.

• The solar radiation absorption layer (a material such as Tinox®) will be preferably inserted in the injection mould tool prior to injection of the rubber filler thermoplastic and over moulded using in-mould lamination techniques to give adherence to the base layer.

• If the two panels are to share the heat collection fluid, water connectors between each of the panels will be preferably inserted into the moulds before injection and over moulded.

The solar absorbing sheet may optionally be only applied to an exterior surface of the panel. In the case of pressure moulding, the sheet may be inserted in a mould for pressure moulding of the panel prior to said pressure moulding.

Embodiments of the present invention are created by injection moulding of the thermoplastic material mixed with the rubber particles. The mixture is passed into a hopper and then into a screw (or ram) type plunger. Heat is applied to the mixture by a heat source and by shear created by mechanical action. The heated mixture is then injected into an appropriate mould.

It may be possible to dose the materials separately depending on the injection moulding unit. Injection moulding gives very good design flexibility. Preferably, where fluid channels are needed in the panel, the panel is moulded in one piece with the channels integral. This application claims priority from GB 1004651 .4, the contents of which, along with the abstract filed herewith are hereby incorporated by reference.