Patent ID: 9650784
Date: 2017-05-16
CPC Classifications: E04B,E04C,E04G

Claim:
1. A modular building unit comprising: a front panel formed of a foamed polyurethane, the front panel comprising an outer surface including an upper portion, a lower portion, and a front taper disposed between the upper portion and the lower portion such that the upper portion is displaced away from a longitudinal centerline of the modular building unit further than the lower portion, wherein the front taper is configured to facilitate removal of the modular building unit from a mold that forms the modular building unit; a back panel formed of the foamed polyurethane, the back panel comprising an outer surface including an upper portion, a lower portion, and a back taper disposed between the upper portion and the lower portion such that the upper portion is displaced away from the longitudinal centerline of the modular building unit further than the lower portion wherein the back taper is configured to facilitate removal of the modular building unit from a mold that forms the modular building unit, wherein a width of the modular building unit between the upper portions of the front and back panels is greater than a width of the modular building unit between the lower portions of the front and back panels; a plurality of support members formed of the foamed polyurethane, the plurality of support members: wherein the foamed polyurethane of the front panel, the back panel, and the plurality of support members is integrally foamed from liquid materials in a single mold that is configured to mold the modular building unit, wherein the modular building unit is configured to stack on top of a second modular building unit with the vertical column cavity aligned with a vertical column cavity of the second modular building unit to form a column of concrete, when poured into the modular building unit, that extends from a bottom opening of the vertical column cavity of the second modular building unit to the top opening of the vertical column cavity, and wherein the horizontal beam cavity at least partially forms a beam of concrete, when poured into the modular building unit, that extends along a length of the modular building unit and intersects with the column of concrete.