CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001 ] This application claims the benefit of U.S. Provisional Patent Application No. 63/341 ,109, filed on May 12, 2022. The entire contents of U.S. Provisional Patent Application No. 63/341 ,109 are incorporated herein by reference for all purposes.

FIELD

[0002] The embodiments described herein are directed to building elements made from recycled agricultural waste products. More particularly, the embodiments provide systems of modular structural panels, and methods of assembling and manufacturing the same.

INTRODUCTION

[0003] The following is not an admission that anything discussed below is part of the prior art or part of the common general knowledge of a person skilled in the art.

[0004] Agricultural waste materials are readily available, accessible, natural, renewable, sustainable, and possess favourable physical properties. For example, com is the most widely planted crop in the world. Corn husks are the inedible leafy shell of corn that are generally stripped from the com cob and discarded. Approximately 45 million tons of com husks are discarded each year. The com husk is composed of many individual fibers. These fibers show a high strength, high elongation, moderate durability, and good pliability.

[0005] Currently, manufacture of pallets for structural or transportation purposes may include the use of wood, paper, cardboard, plant fiber, straw, wastepaper, resin, mineral components, and cellulose fibers. Further manufacturing processes may create a building material that can be formed to any desired shape or size, such as boards, panels, posts, beams, siding, sheathing, trusses, blocks, and shingles.

[0006] However, absent from the industry is a panel system manufactured of a sturdy, environmentally conscious material with the ability to easily assemble together to form durable structures and transportation methods with an increased load capacity. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] For a better understanding of the described embodiments and to show more clearly how they may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:

[0008] FIG. 1 shows a top perspective view of an example modular structural panel, in accordance with an example embodiment;

[0009] FIG. 2 shows a top view of the modular structural panel of FIG. 1 ;

[0010] FIG. 3 shows a bottom perspective view of the modular structural panel of FIG.

1 ;

[0011 ] FIG. 4a shows a zoomed in view of Section A of FIG. 2;

[0012] FIG. 4b shows a zoomed in view of Section B of FIG. 3;

[0013] FIG. 5 shows a top perspective view of a modular structural panel in accordance with another example embodiment;

[0014] FIGS. 6a-6e show multiple top views of an example system of modular structural panels, in accordance with an example embodiment;

[0015] FIG. 7 shows a flowchart of a method of assembling a system of modular structural panels, in accordance with an example embodiment;

[0016] FIG. 8 shows a flowchart of a method of assembling a system of modular structural panels, in accordance with another example embodiment;

[0017] FIG. 9 shows a flowchart of a method of assembling a system of modular structural panels, in accordance with another example embodiment;

[0018] FIG. 10 shows a front perspective view of an example use of two or more modular structural panels, in accordance with an example embodiment;

[0019] FIG. 11 shows a top view of an example modular structural panel, in accordance with another example embodiment;

[0020] FIG. 12 shows a top view of an example modular structural panel, in accordance with another example embodiment; and [0021 ] FIG. 13 shows a front perspective view of an example use of a system of modular structural panels in accordance with at least one embodiment.

[0022] The drawings included herewith are for illustrating various examples of articles, systems, and methods of the teachings of the preset specification and are not intended to limit the scope of what is taught in any way. For simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn to scale. The dimensions of some of the elements may be exaggerated relative to other elements for clarity. It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements or steps, or omitted for repeating instances of like features.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0023] Various apparatuses will be described below to provide an example of one or more embodiments. No embodiment described below limits any claims and any claims may cover apparatuses that differ from those described below. The claims are not limited to apparatuses, methods or systems having all of the features of any one apparatus, method, or system described below or to features common to multiple or all of the apparatuses, methods and systems described below.

[0024] It is possible that an apparatus, system or method described herein is not an embodiment of any claim. Any embodiment disclosed herein that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such embodiment merely by its disclosure in this document.

[0025] The terms "including", "comprising", and variations thereof mean "including but not limited to", unless expressly specified otherwise. A listing of items does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise. The terms "a", "an", and "the" mean "one or more", unless expressly specified otherwise.

[0026] As used herein and in the claims, two or more parts are said to be "coupled", "connected", "attached", “mounted” or "fastened" where the parts are joined or operate together either directly or indirectly (i.e. , through one or more intermediate parts), so long as a link occurs. As used herein and in the claims, two or more parts are said to be "directly coupled", "directly connected", "directly attached", or "directly fastened" where the parts are connected in physical contact with each other. As used herein, two or more parts are said to be "rigidly coupled", "rigidly connected", "rigidly attached", or "rigidly fastened" where the parts are coupled so as to move as one while maintaining a constant orientation relative to each other. None of the terms "coupled", "connected", "attached", “mounted”, and "fastened" distinguish the manner in which two or more parts are joined together.

[0027] Some elements herein may be identified by a part number, which is composed of a base number followed by an alphabetical or subscript-numerical suffix (e.g., 112a, or 1121 ). Multiple elements herein may be identified by part numbers that share a base number in common and that differ by their suffixes (e.g., 1121 , 1122, and 1123). Elements with a common base number may in some cases be referred to collectively or generically using the base number without a suffix (e.g., 112).

[0028] It should be noted that terms of degree such as "substantially", "about", and "approximately" as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree may also be construed as including a deviation of the modified term, such as by 1 %, 2%, 5% or 10%, for example, if this deviation does not negate the meaning of the term it modifies.

[0029] It should also be noted that, as used herein, the wording “and/or” is intended to represent an inclusive-or. That is, “X and/or Y” is intended to mean X or Y or both X and Y, for example. As a further example, “X, Y, and/or Z” is intended to mean X or Y or Z or any combination thereof of X, Y, and Z.

[0030] Furthermore, the recitation of numerical ranges by endpoints herein includes all numbers and fractions subsumed within that range (e.g., 1 to 5 includes 1 , 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is also to be understood that all numbers and fractions thereof are presumed to be modified by the term "about" which means a variation of up to a certain amount of the number to which reference is being made if the end result is not significantly changed, such as 1 %, 2%, 5%, or 10%, for example.

General Description

[0031 ] In some examples, similar references may be used in different figures to denote similar components. In some examples, like features may only be labeled in one instance for simplicity and clarity of the drawings. [0032] Wooden pallets are a ubiquitous element associated with the shipping industry. They facilitate the stacking and movement of bulk goods from manufacturer to consumer, and everywhere in between. However, upon reaching their final destination, wooden pallets are often discarded or burned. Although there are some efforts to repurpose waste wooden pallets, there are numerous limitations. For example, older wooden pallets are treated with chemicals that are hazardous to humans through contact or inhalation. Although newer pallets are generally not treated, they may nonetheless become contaminated through absorption from spills of harmful chemicals during transportation. The wood is similarly a risk of mold or pest infestation. Another limitation includes size variability of the wooden pallets, which are unstable to stack and difficult to dismantle or connect without additional tools and materials. Each of the described limitations make wooden pallets unsuitable or sub-optimal for repurposing such as for the construction of building elements.

[0033] Accordingly, an alternative to traditional wooden pallets is desired. The various embodiments described herein generally relate to systems of modular structural panels, and methods of assembling and manufacturing the same. The modular structural panels and systems thereof can make use of agricultural waste products and seek to overcome the issues with traditional wooden pallets. Specifically, the modular structural panels and systems thereof may provide chemically and biologically resistant, repeatably manufacturable, and stackable pallets, with a load-bearing capacity similar to that of wooden pallets, and modularity conducive to simplified construction of building elements.

Modular Structural Panels

[0034] Reference is now made to FIG. 1 , which illustrates an example modular structural panel 100, in accordance with an example embodiment. The modular structural panel 100 includes a planar surface 110 defining a first plane. The planar surface 110 includes one or more tapered recesses 120a, 120b, 120c located proximate an interior, edge, and/or corner of the planar surface 110. For simplicity and clarity of illustration, repeating instances of each tapered recess type have not been labelled.

[0035] Referring still to FIG. 1 , also shown are connectors 130a, 130b, which connect adjacent modular structural panels 100. The connectors 130a, 130b are shaped and sized to be received in adjacent, aligned tapered recesses of adjacent modular structural panels 100. For example, connector 130a can connect two modular structural panels 100. The two modular structural panels 100 can be aligned such that tapered recesses 120b of each modular structural panel 100 are side-by-side. Connector 130a can then be placed to couple each tapered recess 120b of each modular structural panel 100. In another example, connector 130a can connect two, three, or four modular structural panels 100 at aligned tapered recesses 120c. In such example, multiple modular structural panels 100 can be aligned such that tapered recess 120c of each modular structural panel 100 are side-by-side. Connector 130a can then be coupled to each modular structural panel 100 through tapered recess 120c. Other shapes of connector 130a are possible. For example, connector 130a may be substantially “L”-shaped for connecting three modular structural panels at aligned tapered recesses 120c. Connector 130a may, for example, be substantially shaped as to be at a right angle. In another example, connector 130b can connect two modular structural panels at aligned tapered recesses 120c. When inserted into tapered recesses 120b, 120c, connectors 130a, 130b may be substantially coplanar with the planar surface 110 such that the surface of the modular structural panel 100 is substantially flat. Shapes of tapered recesses 120a, 120b and corresponding connectors 130a, 130b other than those depicted may be possible, such as substantially triangular or circular, for example. Connectors are further described in relation to FIGS. 4a-b, and 6a-e.

[0036] Referring still to FIG. 1 , shown therein are cover plates 140a, 140b, 140c shaped and sized to be received in and cover each tapered recesses 120a-c, respectively. For example, where a recess located proximate an edge or a corner of the planar surface 110 is not to be used to connect modular structural panel 100 to another modular structural panel 100, these may be enclosed by inserting cover plates 140b and 140c, respectively. Recesses located proximate the interior of the planar surface 110 may similarly be enclosed by cover plates 140a. In the embodiment shown, cover plates 140a and 140b are substantially similar to connectors 130a and 130b, respectively. For simplicity, these have been dually labelled in FIG. 1 accordingly. When inserted into tapered recesses 120a-c, cover plates 130a-c may be substantially coplanar with the planar surface 110 such that the surface of the modular structural panel 100 is substantially flat. As disclosed herein, shapes of tapered recesses 120a-c and corresponding cover plates 140a-c other than those depicted may be possible. Cover plates 140a-c are further shown and described in relation to FIGS. 4a-b and 6a-e. [0037] For example, referring briefly to FIGS. 11 and 12, shown therein are top views of example embodiments of modular structural panels 400 and 500, respectively. For simplicity and clarity of illustration, repeating instances of each tapered recess type have not been labelled. Within the planar surface 410 of modular structural panel 400 are tapered recesses 420a, 420b, 420c of which those located proximate the interior are substantially square, and those located proximate an edge or corner are substantially triangular. Within the planar surface 510 of modular structural panel 500 are tapered recesses 520a, 520b, 520c. In this embodiment, the orientation of the tapered recesses 520a-c are substantially similar to those depicted in FIG. 11. However, recesses located proximate the interior and edge are divided into four and two sub-recesses, respectively. Accordingly, in this embodiment all connectors and cover plates may be the same shape and size. Alternative shapes and sizes may be used, for example, to improve the holding strength of the connections and/or produce a particular pattern on the planar surface of the modular structural panel.

[0038] In some embodiments, the two structural panels 100 may be connected using an alternative system to the connectors 130a, 130b. For example, the structural panels 100 may be connected by fasteners, nails, bolts, or any other connecting mechanism. In an example embodiment, structural panels 100 may each have a recess located along a side of the structural panels 100, and a tab located along the opposing side of the structural panels 100. In said embodiments, the tab of a first structural panel 100 may be received by the recess of the second structural panel 100 to connect the structural panels 100 together. Tabs and/or recesses may be included in the structural panels 100 to facilitate connection of the structural panels 100 in any way as desired, such as along adjacent walls or along a single wall.

[0039] Referring now to FIG. 2, shown therein is a top view of the modular structural panel 100 of FIG. 1. As shown, planar surface 110 includes tapered recesses 120a-c. For simplicity and clarity of illustration, repeating instances of each tapered recess type have not been labelled. The interior of tapered recesses will be discussed in greater detail in subsequent sections. Section A of FIG. 2 is discussed in relation to FIG. 4a.

[0040] Reference will now be made to FIG. 3, which shows a bottom view of the modular structural panel 100 of FIG. 1. Shown therein are a plurality of support members 150a, 150b, 150c which can extend opposite the planar surface 110 for supporting the modular structural panel 100. Each support member 150a-c extends to a second plane substantially parallel to the planar surface 110 such that the support members are each substantially the same length. For simplicity and clarity of illustration, repeating instances of each support member type have not been labelled. Section B of FIG. 3 is discussed in relation to FIG. 4b.

[0041 ] As shown in FIG. 3, each tapered recess 120a-c can respectively correspond to a support member 150a-c. For example, each tapered recess 120a located proximate the interior of the planar surface 110 may extend through the planar surface 110 and into a corresponding support member 150a to form a cavity therein. Similarly, each tapered recess 120b located proximate an edge of the planar surface 110 may extend through the planar surface 110 and into a corresponding support member 150b to form a cavity therein. Each tapered recess 120c located proximate a corner of the planar surface 110 may extend through the planar surface 110 and into a corresponding support member 150c to form a cavity therein. In another embodiment, for example, a plurality of hollow support members may be removably coupled to the planar surface beneath each tapered recess.

[0042] Each modular structural panel can further include at least one first set of stringers 172a, 172b, 172cm 172d extending opposite the planar surface 110 between at least two adjacent support members for structural reinforcement of the planar surface. For simplicity and clarity of illustration, repeating instances of each feature have not been labelled. Each stringer in the first set of stringers 172a-d may carry a portion of the load received by the planar surface 110 either in a direction perpendicular to the planar surface 110, such as compressive or tensile loads, or along the first plane of the planar surface, such as shear load. Each stringer in the first set of stringers 172a-d may extend opposite the planar surface 110 to a position between the first plane and the second plane, such that the forks of a forklift may pass beneath them for the purpose of lifting the modular structural panel 100, for example.

[0043] Referring still to FIG. 3, each modular structural panel can further include a second set of stringers 170a, 170b extending opposite the planar surface 110 being substantially perpendicular to the first set of stringers. In at least one embodiment, the second set of stringers 170a, 170b and first set of stringers 172a-d can intersect. In at least one embodiment, the planar surface 110, support members 150a-c, each stringer in the first set of stringers 172a-d, and the second set of stringers 170a, 170b, can be integrally formed. For simplicity and clarity of illustration, repeating instances of each feature have not been labelled.

[0044] In the embodiment shown, the first set of stringers includes one or two outer stringers 172a, 172d, and one or two inner stringers, 172b, 172c, depending on whether they run proximate an edge or the interior of the planar surface 110. Each stringer in the first set of stringers 172a-d may carry a portion of the load received by the planar surface 110 either in a direction perpendicular to the planar surface 110, such as compressive or tensile loads, or along the first plane of the planar surface, such as shear load. Each stringer in the first set of stringers 172a-d may extend opposite the planar surface 110 to a position between the first plane and the second plane, such that the forks of a forklift may pass beneath them for the purpose of lifting the modular structural panel 100, for example.

[0045] In the embodiment shown in FIG. 3, stringers 172b and 172c of the first set of stringers define a channel 180 passing through each support member 150a, 150b. Stringers 172b and 172c can intersect support member 150a and protrude into tapered recess 120b. Where one of the stringers 172b and 172c is absent, such as along an edge of the modular structural panel 100, the channel may be formed by connecting to an adjacent modular structural panel. Each channel 180 may be shaped and sized to receive one of a plurality of structural framing members. For example, the channel may be shaped and sized to receive a 2x4, such as is used in framing a wall. In another example, the channel may be shaped and sized to receive a 2x8, such as is used as a floor joist. Other channel dimensions are possible.

[0046] In the shown embodiment, stringer 170a of the second set of stringers may intersect with a support member 150a and stringers 172b and 172c within a tapered recess 120a. Stringer 170b of the second set of stringers may not intersect with any of the support members 150a-c. In at least one embodiment, stringer 170a does not cross through channel 180, providing a clear path for channel 180 to receive structural framing members. In another embodiment, stringer 170a may cross through support member 150a and channel 180. Stringer 170a, where intersecting support member 150a-c and stringers 172b and 172c, can define at least one slot within the tapered recess 120a-c. In another example embodiment, stringer 170a may be located as to extend between the exterior edges of support members 150a-c. [0047] Other extension distances are possible. For example, each stringer in the first set of stringers 172a-d may extend to the second plane such that the forks of a forklift may only be receivable beneath each stringer of the second set of stringers 170a, 170b. In another example, each stringer in the second set of stringers 170a, 170b may extend to the second plane such that the forks of a forklift may only be receivable beneath in the second set of stringers 172a-d. In yet another example, all stringers may extend to the second plane, and each stringer of the first set of stringers 172a-d and/or the stringers in the second set of stringers 170a, 170b may have a recessed portion defining a slot through which the forks of a forklift may be received.

[0048] Referring now to FIGS. 4a and 4b, shown therein are zoomed in views of Section A and Section B of FIGS. 2 and 3, respectively. Referring to FIG. 4a, shown is a top view of an interior tapered recess 120a, an edge tapered recess 120b and a corner tapered recess 120c of an example embodiment of a modular structural panel. Referring to FIG. 4b, shown is a bottom perspective view of connector 130a/cover plate 140a, connector 130b/cover plate 140b, and cover plate 140c. To clarify the relationship between connectors 130a, 130b and/or cover plates 140a-c with tapered recesses 120a-c, reference to FIGS. 4a and 4b will be made simultaneously. For simplicity and clarity of illustration, repeating instances of each feature have not been labelled, and reference will be made to a single instance intended to be representative of each repeating instance of each feature.

[0049] Tapered recesses 120a-c may comprise a cavity 160a, 160b, 160c. Each tapered recess 120a-c may extend through the planar surface 110 and into a corresponding support member 150a to form a cavity 160a-c therein. In at least one embodiment, each cavity 160a-c can have at least one slot 162a, 162b, 162c. A slot 162a-c may be formed between an inner edge of a cavity 160a-c and stringer 170a, as shown.

[0050] Each connector 130a, 130b can have at least one projection 132a, 132b shaped and sized to engage in the tapered recesses 120a-c. The projections 132a, 132b may extend from a surface opposite that of the planar surface 110. The projections 132a, 132b may be rectangular, square, circular, oval, triangular, or any other applicable shape. Each slot 162a-c may be shaped and sized to receive at least one projection 132a, 132b of each connector in an interference fit to secure two or more modular structural panels together. For example, projection 132a of connector 130a may slidably engage slot 162b of cavity 160b, or slot 162c of cavity 160c. Like projections may be received in like slots. This may be done to secure two adjacent modular structural panels together along their edge, or to secure two, three, or four modular structural panels together at their comers, respectively. Securing multiple structural panels together is further disclosed in relation to FIGS. 6a-e. Similarly, projection 132b of connector 130b may slidably engage slot 162c of cavity 160c to secure two adjacent modular structural panels together at their corners. In at least one embodiment, each connector 130a, 130b may have at least a first projection 132a, 132b and a second projection 134a, 134b.

[0051 ] Each cover plate 140a, 140b, 140c can similarly have at least one projection 142a, 142b, 142c shaped and sized to engage each tapered recess 120a-c so as to secure the cover plate in place. The projections 142a-c may be rectangular, square, circular, oval, triangular, or any other applicable shape. In at least one embodiment, the at least one slot 162a-c of each cavity 160a-c can be further shaped and sized to receive one projection 142a- c of each cover plate in an interference fit to secure the cover plate in place. For example, projection 142a of cover plate 140a may slidably engage slot 162a of cavity 160a to enclose tapered recess 120a. Similarly, projection 142b of cover plate 140b may slidably engage slot 162b of cavity 160b to enclose tapered recess 120b. Projection 142c of cover plate 140c may slidably engage slot 162c of cavity 160c to enclose tapered recess 120c. Like projections may be received in like slots.

[0052] Referring still to FIGS. 4a and 4b simultaneously, in another embodiment, each connector 130a, 130b can have at least two projections 132a and 134a, 132b and 134b located proximate each other. The at least two projections can be shaped and sized to engage each adjoining tapered recess 120a-c so as to secure two or more modular structural panels together. The projections 132a, 134a, 132b, 134b may be rectangular, square, circular, oval, triangular, or any other applicable shape. In the shown embodiment of FIGS. 4a-b, the two projections, 132a and 134a, for example, may be placed within the cavity 160a of the tapered recess 120a. The first projection 132a may slidably engage slot 162a of cavity 160a, while the second projection 134a may be located on the inner surface of stringer 170a, so each projection 132a, 134a straddles stringer 170a, thereby holding the connector 130a in place over tapered recess 120a.

[0053] In another embodiment, each cavity 160a-c can have at least one rail extending across the cavity, each rail shaped and sized to be received between two projections 132a, 134b of each connector 130a, 130b in an interference fit to secure two or more modular structural panels together. In said embodiment, stringer 170a can extend between support members 150a-c and not intersect tapered recesses 120a-c so as to allow for at least one rail to extend across cavity 160a-c.

[0054] Each cover plate 140a-c can similarly have at least two projections 142a-c, 144a, 144b, 144c shaped and sized to engage each tapered recess 120a-c so as to secure the cover plate in place. The projections 142a, 144a, 142b, 144b may be rectangular, square, circular, oval, triangular, or any other applicable shape. In the shown embodiment of FIGS. 4a-b, the two projections, 142a and 144a, for example, may be placed within the cavity 160a of the tapered recess 120a. The first projection 142a may slidably engage slot 162a of cavity 160a, while the second projection 144a may be located on the inner surface of stringer 170a, so each projection 142a, 144a straddles stringer 170a, thereby holding the connector 130a in place over tapered recess 120a.

[0055] In another embodiment, each cavity 160a-c can have at least one rail extending across the cavity, each rail shaped and sized to be received between two projections 142a, 144b of each cover plate 140a, 140b in an interference fit to secure two or more modular structural panels together. In said embodiment, stringer 170a can extend between support members 150a-c and not intersect tapered recesses 120a-c so as to allow for at least one rail to extend across cavity 160a-c.

[0056] Referring now to FIG. 5, shown therein is an example embodiment of the modular structural panel 100 of FIG. 1 , with various tapered recesses enclosed. For example, tapered recesses located proximate the interior of the planar surface 110 have been enclosed by cover plates 140a. Tapered recesses 120b located proximate an edge of the planar surface 110 may be enclosed by cover plates 140b or connectors 130a, and tapered recesses 120c located proximate a corner of the planar surface 110 may be enclosed by connectors 130b or 130a. For simplicity and clarity of illustration, repeating instances of each feature have not been labelled.

[0057] Each modular structural panel can be used as one or more of a pallet, a floor member, or a wall member. For example, FIG. 13 shows an example embodiment wherein multiple modular structural panels are being transported via a forklift as pallets, which have then been connected and installed both as a floor, system of modular structural panels 800, and as a wall, system of modular structural panels 900. Method of Assembling a System of Modular Structural Panel

[0058] Reference will now be made to FIG. 7, which shows a flowchart of an example method 1000 for assembling a system of modular structural panels. To assist with the description of the method 1000, reference will be made simultaneously to FIGS. 6a to 6e. In FIGS. 6a to 6e, each modular structural panel is substantially similar to modular structural panel 100 as described in FIGS. 1 to 5, with like features labeled in increments of 100. For simplicity and clarity of illustration, repeating instances of each feature have not been labelled.

[0059] At Step 1010, shown in FIG. 6a, a first modular structural panel 100 is positioned adjacent to a second modular structural panel 200.

[0060] At Step 1020, shown in FIG. 6b, a first edge 102 of the first modular structural panel 100 is positioned to abut against a first edge 202 of the second modular structural panel 200.

[0061 ] At Step 1030, shown in FIG. 6b, each support member corresponding to tapered recesses 120b and 120c proximate the first edge 102 of the first modular structural panel 100 is substantially aligned with each support member corresponding to tapered recesses 220b and 220c proximate the first edge 202 of the second modular structural panel 200.

[0062] At Step 1040, shown in FIG. 6c, the first modular structural panel 100 is detachably connected to the second modular structural panel 200 along the abutting edge 102, 202 by inserting at least one connector 130a-b in each of the plurality of adjoining tapered recess 120b-c, 220b-c. In the embodiment shown in FIG. 6b-c, connector 130a can be inserted in adjoining tapered recesses 120b and 220b. Adjoining tapered recesses 120c and 220c may similarly be connected by connector 130a or 130b, depending on whether they are to be connected to an additional modular structural panel. For example, in one embodiment where only a first modular structural panel 100 and a second modular structural panel 200 are coupled, connector 130b may be placed within adjoining tapered recesses 120c and 220c. In another embodiment, for example, where more than two modular structural panels may be coupled, connector 130a may be placed within adjoining tapered recesses 120c and 220c. In said embodiment, connector 130a may be used to couple two further modular structural panels. [0063] At optional Step 1050, shown in FIG. 6c-d, the tapered recesses 120a, 120b, 120c, 220a, 220b, 220c that are independent of any adjacent tapered recess can be covered by inserting at least one cover plate 140a, 140b. Tapered recesses 120b, 120c, 220b, 220c that are to adjoin an adjacent tapered recess can be covered by at least one connector 130a, 130b, 130c. T FIG. 6d shows modular structural panels 100 and 200 connected along their respective first edge 102, 104, with all tapered recesses closed. Planar surface 110 and planar surface 210, as well as each cover plate and connector, can be substantially coplanar with the first plane such that the planar surfaces 110, 210 are substantially flat. In another embodiment, an additional modular structural panel may be connected to any of a second edge 104 or a fourth edge 108 of modular structural panel 100, or a second edge 204, a third edge 206, or a fourth edge 208 of modular structural panel 200. A third edge 106 of modular structural panel 100 is shown to be enclosed by cover plates and therefore is unavailable to connect to an additional modular structural panel. This may be done for various reasons, such as along a finished edge, for example. Other connector and cover plate configurations are possible, depending on the number and location of additional modular structural panels to be connected. For example, this may depend on the intended use of the system of modular structural panels. In the embodiments shown, the modular structural panels are substantially square. In some embodiments, for example, other panel shapes may be possible such as triangular or hexagonal.

[0064] At optional Step 1060, shown in FIG. 6e, Steps 1010 to 1050 can be repeated for each additional modular structural panel to be added to the system of modular structural panels. Shown therein is a system of modular structural panels after repeating Steps 1010 to 1050 as depicted in FIGS. 6a to 6d, the system now including three modular structural panels 100, 200, 300. Planar surfaces 110, 210, 310, as well as each cover plate and connector, can be substantially coplanar with the first plane such that the planar surfaces 110, 210, 310 are substantially flat.

[0065] Reference is now made to FIG. 8, which shows another example method 1100 for assembling a system of modular structural panels. Method 1100 steps corresponding to method 1000 steps have been similarly numbered. Steps 1010, 1020, and 1030 of method 1000 are substantially similar to steps 1110, 1120, and 1130 in method 1100. To assist with the description of the method 1100, reference will be made simultaneously to FIGS. 4a to 4b and again to 6a to 6e. [0066] At Step 1140, shown in FIGS. 4a-b and 6b-c, the first modular structural panel 100 can be detachably connected to the second modular structural panel 200 along the abutting edge 102, 202. At least one connector 130a, 130b is inserted in each adjoining tapered recess, where at least one projection 132a, 132b is slidably engaged in the at least one slot 162b, 162c in the cavity 160b, 160c of the first modular structural panel 100 and the second modular structural panel 200. Each aligned support member corresponds to a tapered recess 120b, 120c along the abutting edge 102, 202. Adjoining recesses 120b, 220b and 120c, 220c may be connected using either of connectors 130a, 130b as described herein.

[0067] At optional Step 1150, shown in FIGS. 4a-b and 6c-d, the tapered recesses 120a-c, 220a-c, that are independent of any adjacent tapered recess can be covered by inserting at least one cover plate 140a-c. At least one projection 142a-c of the at least one cover plate 140a-c may be slidably engaged in the at least one slot 162a-c in the cavity 160a- c of each support member. Support members along the abutting edge 102, 202 may not be covered with a cover plate 140a-c. Tapered recesses 120b, 120c, 220b, 220c that are to adjoin an adjacent tapered recess can be covered by at least one connector 130a, 130b.

[0068] At optional Step 1160, Steps 1110 to 1150 can be repeated for each additional modular structural panel to be added to the system of modular structural panels.

[0069] Reference is now made to FIG. 9, which shows another example method 1200 for assembling a system of modular structural panels. Method 1200 steps corresponding to method 1000 steps have been similarly numbered. Steps 1010, 1020, and 1030 of method 1000 are substantially similar to steps 1210, 1220, and 1230 in method 1200. To assist with the description of the method 1200, reference will again be made simultaneously to FIGS. 4a to 4b and to 6a to 6e.

[0070] At Step 1240, shown in FIGS. 4a-b and 6b-c, the first modular structural panel 100 can be detachably connected to the second modular structural panel 200 along the abutting edge 102, 202. At least one connector 130a, 130b can be inserted in each adjoining tapered recess, where at least one rail in the cavity 160b, 160c of each aligned support member corresponding to a tapered recess 120b, 120c along the abutting edge 102, 202 may be slidably engaged between at least two projections 134a, 134b. Adjoining recesses 120b, 220b and 120c, 220c may be connected using either of connectors 130a, 130b as described herein.

[0071 ] At optional Step 1250, shown in FIGS. 4a-b and 6c-d, the tapered recesses 120a-c, 220a-c that are independent of any adjacent tapered recess can be covered by inserting at least one cover plate 140a-c. At least one rail in the cavity 160a-c of each support member, other than the support members along the abutting edge 102, 202, may be slidably engaged between at least two connector projections 144a-c. Tapered recesses 120b, 120c, 220b, 220c that are to adjoin an adjacent tapered recess can be covered by at least one connector 130a-c.

[0072] At optional Step 1260, Steps 1210 to 1250 can be repeated for each additional modular structural panel to be added to the system of modular structural panels.

[0073] In at least one embodiment of any of methods 1000, 1100, 1200, the method can further include orienting the system of modular structural panels horizontally for use as a floor. In one example embodiment, this may be performed on an ongoing basis as the system of modular structural panels is built across a floor. In said example, the system of modular structural panels may be built on top of an existing floor or subfloor In another example embodiment, this may be performed on an ongoing basis while inserting a structural framing member, such as a 2x8 floor joist, for example, through each channel 180 as seen in FIG. 1.. In said example, the system modular structural panels may make the floor. Other horizontally oriented assemblies, and methods of assembling thereof, are possible.

[0074] In at least one embodiment of any of methods 1000, 1100, 1200, the method can further include orienting the system of modular structural panels vertically for use as a wall. In one example embodiment, this may be performed by erecting a series of vertical framing members, such as 2x4 wall studs, and sliding each vertical frame member through each channel 180 of each modular structural panel to systematically build the wall vertically. In another example embodiment, this may be performed by first assembling the system of modular structural panels horizontally, inserting the vertical framing members into each channel 180 while still oriented horizontally, and subsequently erecting the completed wall by lifting the system of modular structural panels from the horizontal orientation to the vertical orientation. Other vertically oriented assemblies, and methods of assembling thereof, are possible. [0075] Referring now to FIG. 10, shown therein is an example embodiment of a system of modular structural panels wherein multiple modular structural panels substantially similar to modular structural panel 100 of FIG. 1 are stacked for storage and/or use as a pallet. In the embodiment shown, the support members of an upper modular structural panel and the recess of a lower modular structural panel can be complementary such that the upper support members nest in the lower recesses. For example, support member 650b of modular structural panel 600 is nested in tapered recess 720b of modular structural panel 700 beneath it. Support member 650c is similarly nested in tapered recess 720c. This may provide various benefits such as improved stability in transport as well as the strength and stability of a multilayered wall or floor system of modular panels, for example.

[0076] In at least one embodiment, the nesting of structural panel 600 into structural panel 700 may allow for nesting capability to reach a depth as low as This may allow for a reduced requirement of shipping space, as an increased number of structural panels may be nested in the space previously used for a smaller number of structural panels. For example, a structural panel may have dimensions of 40 inches by 48 inches. In more traditional situations, the structural panels may be stacked 40 structural panels in height across 27 lifts, which is the lift capacity for a 53 foot trailer. This may lead to a maximum of 1 ,080 structural panels per trailer. When considering the nesting capacity of structural panels 600, 700 at a depth as low as 146 structural panels may be stacked in heigh across the 27 lifts. This may result in as many as 3,982 structural panels per trailer. The increased capacity of the shipping trailers may reduce environmental impacts of shipping as well as costs to ship.

[0077] In at least one embodiment, the method can further include orienting a first system of modular structural panels horizontally for use as a floor as described herein and orienting a second system of modular structural panels vertically for use as a wall as described herein. The first and second system of modular structural panels may then be connected, for example, using a plurality of 90-degree connectors inserted in the adjoining tapered recesses of adjacent support members. Other means of connection are possible, such as through one or more intermediate framing members 194 as shown in FIG. 13.

[0078] Referring now to FIG. 13, shown therein is a first system of modular structural panels 800 oriented for use as a floor and a second system of modular structural panels 900 oriented for use as a wall. Also shown therein are vertical framing members 190 and horizontal framing members 192, which can be seen passing through channel 180 as depicted in FIG. 1 .

[0079] Uses other than as a floor, wall, or pallet are possible. For example, one or more modular structural panels can have all recesses enclosed to produce a substantially flat surface for use as a table, bed, or other furniture. In another example, a system of modular structural panels may be oriented on an angle, such as for use as a roof.

Method of Manufacturing

[0080] In at least one embodiment, each modular structural panel can be made of a mix of resin and agriculture waste material. The ratio of resin to agricultural waste material can be at least 50% resin to at least 50% agricultural waste material. For example, the ratio may be 50% resin to 50% agricultural waste material, or 75% resin to 25% agricultural waste material. Other ratios may be possible. The ratio may depend on the desired physical, chemical, and biological properties of the modular structural panel.

[0081 ] In some embodiments, the agricultural waste may be a plurality of corn fibers extracted from corned husks. The plurality of com fibers can be any length and orientation. For example, the plurality of corn fibers can be long continuous strands. The plurality of corn fibers also be unidirectionally oriented, bidirectionally oriented, or multi-directionally oriented across the planar surface. In another example, the plurality of corn fibers can be short segments. In such an embodiment, the plurality of com fibers can be randomly oriented across the planar surface. The length and orientation of the plurality of com fibers can be substantially similar or different in the plurality of support members and/or stringers as in the planar surface. This may depend, for example, on the whether these features are integrally formed or individually formed and subsequently assembled.

[0082] In some embodiments, the agricultural waste may be a plurality of hemp fibers. The hemp fibers can be any length and orientation. For example, the hemp fibers can be long continuous strands. The hemp fibers also be unidirectionally oriented, bidirectionally oriented, or multi-directionally oriented across the planar surface. In another example, the hemp fibers can be short segments. In such an embodiment, the hemp fibers can be randomly oriented across the planar surface. The length and orientation of the hemp fibers can be substantially similar or different in the plurality of support members and/or stringers as in the planar surface. This may depend, for example, on the whether these features are integrally formed or individually formed and subsequently assembled.

[0083] In at least one embodiment, each modular structural panel can be compression molded. This may be conducive to manufacturing with any length and/or orientation of the plurality of corn fibers.

[0084] In at least one embodiment, the modular structural panel 100 can be integrally formed.

[0085] In at least one embodiment, each modular structural panel can be injection molded. This may be limited to manufacturing with only a plurality of short, randomly oriented corn fiber segments.

[0086] In one embodiment, a product design is created based on the modular structural panel. A mold may be fabricated to create a negative cavity for the product design. For example, the negative cavity of a created mold may be of the size and shape of the modular structural panel. In another example, the negative cavity may be of the size and shape of a connector (such as connector 130a, 130b) or a cover plate (such as cover plate 140a, 140b).

[0087] In some embodiments, there may be multiple molds used to create the full mold for the modular structural panel. For example, the modular structural panel may be molded from four individual, smaller molds. In said embodiments, after injection molding, the individual pieces may be joined together to create the modular structural panel. For example, the pieces may be snapped, bolted, screwed, or fastened in any other way, together to form the full structural panel. In some embodiments, the modular structural panel may be manufactured from as little as one mold up to as many individual molds as required to form the modular structural panel.

[0088] The mold may be manufactured from specific grades of steel and aluminum designed to withstand a high number of heating and cooling cycles, such as 6063 aluminum, P20 steel, H13 steel, 420 stainless steel, or any other steel or aluminum grade. In some embodiments, the mold consists of two parts to be clamped together.

[0089] The manufactured mold for the modular structural panel, the connectors and/or the cover plate may be placed within an injection molding machine. The injection molding machine may be made of a material hopper, barrel, injection ram/rotating screw, heating device, moveable pattern, and ejectors, along with the manufactured mold.

[0090] To begin the injection molding process, the manufactured mold may be securely closed into the clamping unit of the injection molding machine. The clamping unit may keep the manufactured mold halves together to keep the mold air tight while the panel material is injected. The clamping unit may be used to open and close a die and eject the formed parts. In some embodiments, the clamping unit is a toggle type. In some embodiments, the clamping unit is a straight-hydraulic type.

[0091 ] Once the manufactured mold is clamped within the clamping unit, the panel material may be fed into the injection molding machined and conveyed or augured towards the mold. The panel material that is fed into the injection molding machine may be of the amount as to only fill the manufactured mold. The panel material may be of any of the mixtures of resin and agricultural waste as disclosed. In some embodiments, the panel material may be in the form of pellets.

[0092] The panel material may travel towards the mold through the barrel of the injection molding machine via the injection ram/rotating screw. Heated zones within the barrel may cause the panel material to heat up by temperature and compression into a molten material.

[0093] The panel material may then be inserted into the mold within the clamping unit in the molten state. Once the panel material contacts the interior of the mold surfaces, the cooling process begins. The cooling process may solidify the shape and rigidity of the manufactured part. The clamping unit may keep the manufactured part in place unit the required cooling time has elapsed.

[0094] Once the cooling time has elapsed, the injection molding machine may eject the manufactured part from the mold with an ejection system. The part may be pushed out of the mold using a necessary force for ejection.

[0095] Once the manufactured part has been ejected from the injection molding machine, the process may repeat as many times as required. Physical, Chemical, and Biological Properties

[0096] The physical, chemical, and biological properties of a modular structural panel as described herein may vary depending on the ratio of resin to fibers. For example, a greater ratio of resin to fibers may have better/worse chemical and biological properties, but better/worse physical properties.

[0097] Various embodiments have been described herein by way of example only. Various modification and variations may be made to these example embodiments without departing from the spirit and scope of the invention, which is limited only by the appended claims.