US20070193212A1 - Engineered structural members and methods for constructing same - Google Patents
Engineered structural members and methods for constructing same Download PDFInfo
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- US20070193212A1 US20070193212A1 US11/696,122 US69612207A US2007193212A1 US 20070193212 A1 US20070193212 A1 US 20070193212A1 US 69612207 A US69612207 A US 69612207A US 2007193212 A1 US2007193212 A1 US 2007193212A1
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- structural
- reinforcing member
- joist
- flange
- arm
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/30—Columns; Pillars; Struts
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0408—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section
- E04C2003/0413—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section being built up from several parts
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0426—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section
- E04C2003/043—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section the hollow cross-section comprising at least one enclosed cavity
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0426—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section
- E04C2003/0434—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section the open cross-section free of enclosed cavities
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0426—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section
- E04C2003/0439—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section the cross-section comprising open parts and hollow parts
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
- E04C2003/0447—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section circular- or oval-shaped
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
- E04C2003/0452—H- or I-shaped
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
- E04C2003/0465—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section square- or rectangular-shaped
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
- E04C2003/0469—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section triangular-shaped
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
- E04C2003/0478—X-shaped
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49616—Structural member making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49616—Structural member making
- Y10T29/49623—Static structure, e.g., a building component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49616—Structural member making
- Y10T29/49623—Static structure, e.g., a building component
- Y10T29/49625—Openwork, e.g., a truss, joist, frame, lattice-type or box beam
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4998—Combined manufacture including applying or shaping of fluent material
- Y10T29/49982—Coating
Abstract
A system and method of manufacture providing reinforced structurally functional load-bearing members, including but not limited to using thermoplastic materials, such as High Density Polyethylene (HDPE), reinforced such as with an aluminum alloy or carbon fiber core element. Among its possible uses, the present invention has application for provision of structural support members, such as an illustrative I-joist product having a vertical center member preferably comprising HDPE, and top and bottom flanges having structurally meaningful reinforcement. The center member and flanges preferably comprising HDPE provides a relatively hard, durable, substantially weather-resistant structure.
Description
- This application is a Divisional of U.S. application Ser. No. 11/194,973, filed Aug. 2, 2005, which claims the benefit of U.S. Provisional Application No. 60/598,014 filed on Aug. 2, 2004, U.S. Provisional Application No. 60/644,451 filed on Jan. 14, 2005, and U.S. Provisional Application No. 60/686,870 filed on Jun. 1, 2005, the entire disclosures of which are incorporated herein by reference in their entirety.
- The present invention is directed to construction materials, and more particularly, to structural members, such as joists, posts and beams, as well as methods of manufacturing the same.
- Use of engineered materials, such as wood composites and various plastics, including recyclable thermoplastic, such as high-density polyethylene (HDPE), is becoming increasingly popular in the construction industry. These uses encompass various horizontal and vertical applications that meet a range of present decorative and/or structural construction needs.
- Structural members, such as joists, beams and the like, are currently available as wood lumber, a valuable yet limited resource with no recycling capability, as plastic lumber, and as reinforced or composite lumber. Composites often include wood fiber or fiberglass in a plastic matrix, or wood composites such as I-joist products having oriented strand board with micro-laminated top and bottom flanges.
- Wood-containing products generally are sensitive to environmental conditions, such as the effect of moisture. Such sensitivity must be accounted for during design, installation and use. There are various recyclable thermoplastic products available which are generally less sensitive to environmental conditions, specifically to the effect of moisture, than wood and composite products. Design benefits follow accordingly.
- HDPE resins are used in a variety of blow molding, rotational molding, and extruded applications for liquid food containers, automotive fuel tanks, and large volume drums. HDPE is widely known as the material of choice for recyclable milk containers. It is also widely used for pipelines for water or other solution distribution systems, and for liners for landfills, water, or other solution holding ponds.
- U.S. Plastic Lumber Corporation provides a fiberglass reinforced HDPE product that is available in sizes and shapes of standard lumber. These plastic lumber products are typically heavy and contain fiberglass fibers that can quickly dull saw blades and drill bits of construction equipment used to size the materials. Other known HDPE I-joists contain hollow cores with wide flanges that are not conducive to easy cutting-to-dimension with standard construction tools, nor fit with standard fasteners.
- Accordingly, there is a need for structural members, including joists, beams, posts and the like, that are preferably made of a weather-resistant recyclable material and that provide adequate structural performance while not being too heavy or large for practical use. In addition, there is a need for providing reinforced structural members that provide adequate structural performance and that can be worked with standard construction equipment without unduly dulling cutting blades and drill bits. There is a further need for such members to be available in either standard and custom sizes and ratings, on demand or as needed, and with the possibility of working the engineering tradeoff between strength and weight in use of engineered materials, such as HDPE.
- One aspect of the present invention relates to load-bearing systems, and methods of manufacture, that provide structurally functional, load-bearing assemblies. Embodiments of the invention include, but are not limited to, thermoplastic structural materials such as HDPE in a form that is reinforced with a rigidifying portion, such as an aluminum, aluminum alloy, or carbon fiber core.
- More specifically, novel structural members may include various joists, beams, posts and the like, having sufficient strength and deflection characteristics for use in structural applications, such as framing, for decking and the like. Such structural members are comparatively lighter in weight as compared to currently available fiber-reinforced plastic lumber products and are more weather-resistant compared to wood and wood-composite products.
- An illustrative I-joist product in one aspect of the present invention defines a vertical center member preferably including HDPE, and top and bottom flanges interconnected to the vertical center member, also including HDPE. The HDPE provides a relatively hard, durable, substantially weather-resistant structure. The flanges form a system having structural vigor and enable the HDPE-based system to provide sufficient strength, construction flexibility, and true alignment (i.e., true to specification).
- In accordance with other embodiments of the present invention, such I-joists are provided that adequately support loads for indoor and/or outdoor decking, flooring, and other support systems. Webbing may be formed with or as a rigid member and may be combined with top and bottom flanges of a relatively hard, durable, flexible, and substantially weather-proof material. Preferred materials include either virgin and/or recycled HDPE, surrounding a suitable rigidizing core component, such as of an aluminum alloy. Use of recyclable material, such as HDPE, enables cut waste to be recycled. This recycling meets and adheres to current “Green Build” objectives, and is environmentally proactive. Therefore, the present invention not only achieves the design criteria required for support, but also provides a framework suitable for re-use of components in the future.
- In various embodiments, webbing and top and bottom flanges of I-joists are manufactured with various dimensions and characteristics and with various materials to achieve maximum transfer of loading with minimal to no vertical or horizontal movement of the finished joist, as specified, while standard construction tools can be used to cut the product to desired dimensions.
- Preferably, the load-bearing members, for example, the top and bottom flanges of an I-joist, contain a strengthening core material or other channel or flange reinforcing members so as to stabilize the member and to assist in load-bearing. Thus, depending on load requirements, either or both the top and/or bottom flanges of an I-joist of the invention may contain one or more of various reinforcing members, which may include aluminum or other alloys, or other materials such as carbon fiber, and may include rods, C- and/or M-shaped channels, channels with center slot, or other configurations, for supplying a desired structural reinforcement.
- Load-bearing HDPE embodiments of the present invention weather exceptionally well and do not absorb moisture. Therefore the present invention may be freely utilized for both indoor and outdoor support structures.
- In various embodiments, vertical and/or horizontal support members of the invention may replace wood and/or composite material members, and may have hollow or solid cores depending upon the application and need, while also being configurable in custom and/or standard sizes. For example, boards, studs, posts and beams can be provided as standard 2×4, 4×4, 6×6 (values in inches) sized lumber, and joists, rim joists, and beams can be provided as standard 2×8, 2×10, 2×12 sized lumber, while engineered I-joists can be provided as standard sized 9½ or 11⅞ members with 2 1/16 flanges. It is advantageous that such standard sizes will enable use of conventional fasteners and other hanging hardware.
- In several embodiments of the invention, structural members are configured to meet given design specifications, which may be custom or customary specifications. Structural configuration and use may be anticipated accordingly during the manufacture process, or can be adjusted before installation by selection or by adding strengthening components.
- Joists according to the invention therefore may be supplied having specifications that enable center-to-center spacing selected according to project needs and design specifications while still providing substantially straight and true structural framing. These structural members can be delivered to specification without the need for trimming and truing as per wood lumber, and with minimal cutting but for length adjustments, if needed. This flexibility and reliability is uncommon to lumber products.
- Another aspect of the present invention may also include an extrusion process for extruding load members, and further provides a dual extrusion process wherein a reinforcing member, such as an aluminum alloy, is extruded with a specified shape, cooled, prepared for receipt of the HPDE, and the HDPE is then extruded around the reinforcing member, with an option of also within the reinforcing member, and then cooled, all within a continuous process, to form a structural assembly or member of the invention.
- In certain embodiments of the invention, the extruded aluminum, other alloy component, or carbon fiber reinforcing member may comprise an outer surface that includes a configuration for enhanced bonding between itself and the HDPE. This may include scarification of the surface, apertures in the surface, application of bonding tape, provision of ribs or other non-flat surface features, or the like, to provide a bonding and adhesion surface for the HDPE. Improved bonding between the aluminum and HDPE can improve the load bearing rating of the final product.
- For at least one embodiment of the present invention having a reinforcing member with a plurality of arms, the reinforcing member is shaped such that with embedding of the reinforcing member, the reinforcing member can produce a mechanical bond with the HDPE or other surrounding material. The reinforcing member may comprise apertures or ribbing to aid in developing a sufficient mechanical bond between the HDPE and the reinforcing member, thereby removing the need for adhesive bonding or scarification of the reinforcing member, although adhesive bonding of the reinforcing member to the HDPE, and/or scarification of the surface of the reinforcing member are also optional.
- The extrusion process can be enabled to provide various lengths of product as desired, thereby maximizing shipping efficiency. Typically, 60 foot lengths would optimally fill a rail car load, while 40 foot lengths would be desired for a trailer truck load.
- Thus, in accordance with various embodiments of the present invention, a structural joist adapted for use in a building structure is provided, the joist comprising a substantially solid vertical center member comprising a thermoplastic material and having a longitudinal axis, and a top flange and a bottom flange interconnected to said vertical center member and extending substantially the entire length of the longitudinal axis, the top flange and the bottom flange comprising a thermoplastic material. In addition, the joist comprises an outer top flange interconnected to the top flange and extending substantially an entire length of the longitudinal axis, and an outer bottom flange interconnected to the bottom flange and extending substantially the entire length of the longitudinal axis. In addition, the joist comprises a metallic non-planar channel member operatively associated with at least one of the top flange, the bottom flange, the outer top flange, or the outer bottom flange, the channel member extending substantially the entire length of the longitudinal axis.
- Further embodiments of the present invention also include a joist with outer flanges, with an optional channel member. Thus, in accordance with embodiments of the present invention, an I-joist adapted for use in a building structure is provide, the I-joist comprising an intermediate member having a longitudinal axis and a top flange and a bottom flange, an outer top flange interconnected to the top flange and extending substantially an entire length of the longitudinal axis, and an outer bottom flange interconnected to the bottom flange and extending substantially the entire length of the longitudinal axis.
- At least one method of manufacturing a joist having outer flanges is provided herein, the method of manufacturing a joist comprising providing a vertical center member having a top flange and a bottom flange, providing an outer top flange have a receptacle for receiving the top flange, providing an outer bottom flange have a receptacle for receiving the bottom flange, positioning the top flange in the receptacle of outer top flange, and positioning the bottom flange in the receptacle of outer bottom flange. A reinforcing channel member may also be added as part of the method of manufacturing.
- Various embodiments of the present invention may also include joists without outer flanges. Thus, in accordance with embodiments of the present invention, a structural joist is provided comprising a vertical center member, a top flange and a bottom flange connected to the vertical center member, and a reinforcing member substantially embedded within at least one of the top flange and the bottom flange, the reinforcing member extending along substantially an entire length of a longitudinal axis of the at least one of the top flange and the bottom flange, wherein a strength of the structural joist is increased.
- Other embodiments of the present invention may include a reinforcing member used in various structures, such as post and joists, wherein the reinforcing member includes a plurality of arms. Thus in accordance with embodiments of the present invention, a structural member is provided, the member comprising a thermoplastic outer member having a longitudinal length; and at least one reinforcing member located within the thermoplastic outer member and extending substantially along the longitudinal length of the thermoplastic outer member, the reinforcing member comprising a plurality of arms.
- Another embodiment of the present invention may also include an I-joist, wherein the I-joist comprises a webbing having a longitudinal length, with a top flange connected proximate a first end of the webbing and a bottom flange connected proximate a second end of the webbing, and wherein the top and bottom flanges extend along the longitudinal length. In addition, the I-joist includes at least one reinforcing member located within at least one of the top flange and the bottom flange, the reinforcing member extending substantially along the longitudinal length, and the reinforcing member comprising a plurality of arms.
- Among other embodiments of the present invention described herein, an additional method of manufacture is provided for manufacturing a structural support member having a rated deflection loading. The method comprises preparing a structural reinforcing member of at least length L for bonded integration into a structural support member of at least length L, and forming a structural support member preform by feeding the structural reinforcing member into a thermoplastic extruder and extruding the structural reinforcing member with a thermoplastic, wherein the thermoplastic is bonded to the surface of the structural reinforcing member along the length of at least L. In addition, the method comprises controlled cooling of the extrusion-formed structural support member preform wherein the thermoplastic is bonded to the structural reinforcing member along the length of at least L and wherein the bonded thermoplastic and structural reinforcing member share the loading of the structural support member without separating along the at least length L when the structural support member is loaded to the rated deflection loading.
- Various embodiments of the present invention are set forth in the attached figures and in the detailed description of the invention as provided herein and as embodied by the claims. It should be understood, however, that this Summary Of The Invention may not contain all of the aspects and embodiments of the present invention, is not meant to be limiting or restrictive in any manner, and that Invention as disclosed herein is and will be understood by those of ordinary skill in the art to encompass obvious improvements and modifications thereto.
- Additional advantages of the present invention will become readily apparent from the following discussion, particularly when taken together with the accompanying drawings.
- Various advantages and benefits of the present invention will be better understood when considered in conjunction with the following detailed description, making reference to the drawings that are not necessarily to scale, wherein:
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FIG. 1 is a perspective view of an illustrative I-joist in accordance with embodiments of the present invention; -
FIG. 2 is a perspective view of an upper outer flange of the I-joist depicted inFIG. 1 ; -
FIG. 3 is a perspective view of a lower outer flange of the I-joist depicted inFIG. 1 ; -
FIG. 4 is a perspective view of an I-joist in accordance with embodiments of the present invention; -
FIG. 5 is a perspective view of a channel reinforcing member of the I-joist depicted inFIG. 4 ; -
FIG. 6 is a perspective view of an I-joist in accordance with embodiments of the present invention; -
FIG. 7 is a perspective view of an I-joist in accordance with embodiments of the present invention; -
FIG. 8 is a perspective view of flange reinforcing members of the I-joist depicted inFIG. 7 ; -
FIGS. 9-11A are perspective views of I-joists in accordance with embodiments of the present invention; -
FIG. 11B is an end, side elevation view of a flange of an I-joist having an alternate embodiment of a reinforcing member; -
FIG. 12 is a perspective view of an I-joist having gusset reinforcing members in accordance with embodiments of the present invention; -
FIG. 13 is a side elevation of an I-joist having side vertical reinforcing members in accordance with embodiments of the present invention; -
FIG. 14 is a side elevation of an I-joist having webbing with knockouts in accordance with embodiments of the present invention; -
FIGS. 15A-15G are perspective views of posts (or reinforced portions of structural members) having core reinforcing members in accordance with embodiments of the present invention; -
FIGS. 16-20 show illustrative reinforcement embodiments of the present invention, the reinforcing members suitable for use in the flange portion of I-joists, as well as in posts; -
FIG. 21 is an end, side elevation view of an I-joist in accordance with embodiments of the present invention; -
FIG. 22 is an end, side elevation view of yet another I-joist in accordance with embodiments of the present invention; -
FIG. 23 is an end, side elevation view of a rim joist in accordance with embodiments of the present invention; -
FIG. 24 is a side elevation view a web and flange reinforcing member in accordance with embodiments of the present invention; and -
FIG. 25 shows illustrative method of the present invention. - Referring now to
FIG. 1 , in accordance with embodiments of the present invention, an illustrative I-joiststructural member 10 is shown. I-joist 10 includes aweb member 13.Web member 13 has a central web orwebbing 14, anupper flange 18, and alower flange 22, whereinflanges webbing 14. - As part of a typical I-joist, webbing 14 interacts as a load-bearing member with load-bearing upper and
lower flanges web member 13 includeswebbing 14,upper flange 18 andlower flange 22 formed of a relatively hard, durable, flexible, and substantially weather-proof material, including but not limited to thermoplastics, such as HDPE, and/or thermoplastic composite materials, such as HDPE with additives such as, for example, natural or man-made fibers or particles of various materials/compositions, including but not limited to wood particles and/or fiberglass strands. Preferablyweb member 13 is extruded. - I-
joist 10 also includes an upperouter flange 26 that is interconnected toupper flange 18 to formupper flange assembly 27 and a lowerouter flange 30 that is interconnected tolower flange 22 to fromlower flange assembly 29. Provision of theseflange assemblies joist 10. - Typically,
upper flange 18 andlower flange 22 are similar in cross-section but they may be dissimilar according to design specifications as needed. Likewise, typically outerupper flange 26 and outerlower flange 30 are similar in cross-section but they may be dissimilar according to design specifications as needed. - Alternatively webbing 14,
upper flange 18, andlower flange 22 are not integrally formed and may be separately manufactured and then interconnected. For separately extruded parts, interconnection may be by extrusion welding or the like, thus to formweb member 13. -
Outer flanges upper flange 18 andlower flange 22, respectively, in an integrated manufacturing process or may be separately formed and then mated (e.g., slid) in place and then interconnected, such as by extrusion welding or the like. One advantage of separate components is that a single supply can be used for both outer flanges for an I-joist with symmetrical cross-section, which may provide some cost savings. Alternatively, each component may be separately specified, to provide specialized configurations, as needed, without having to interrupt regular extrusion production runs. Such flexibility enables meeting various architectural and custom design goals while providing some cost savings. - Referring again to
FIGS. 1-3 ,upper flange 18 cooperates with its connection to webbing 14 to form a key 38. More particularly,upper flange 18, as it extends from and in cooperation withwebbing 14, forms key 38. Accordingly, upperouter flange 26 includes areceptacle 34 that internally substantially corresponds in shape (i.e., cross section) to the external shape ofkey 38. - Likewise,
lower flange 22 andwebbing 14 form a key 42, and lowerouter flange 30 includesreceptacle 46 that internally substantially corresponds in shape to the external shape ofkey 42. Receptacle andkey pairs form locking mechanisms - Locking
mechanism 39 enablesflanges mechanism 43 enablesflanges -
Outer flanges joist 10. In accordance with preferred embodiments of the present invention,outer flanges -
Webbing 14 is preferably solid, but may be a lattice, slotted or otherwise apertured, depending on the surrounding application environment, needs of the construction project, load-bearing specifications, and overall construction objectives, and may be formed of various suitable load-bearing materials, such as HDPE, aluminum or the like. - Referring now to
FIGS. 4-5 , in accordance with embodiments of the present invention, an I-joiststructural member 60 is shown that is similar to I-joist 10 described with respect toFIG. 1 , and further includeschannel reinforcing members - By way of example and not limitation,
channel reinforcing member opening 68 along one side. The shape of eachchannel reinforcing member upper flange 18 andlower flange 22, respectively, prior to, or in combination with interconnecting withouter flanges channel reinforcing members joist 60.Channel reinforcing members joist 60. - Referring now to
FIG. 6 , an I-joiststructural member 70 in accordance with embodiments of the present invention is shown. I-joist 70 includeswebbing 14 having an integratedupper flange 74 andlower flange 78, whereflanges flanges joist 10. - Preferred embodiments of the invention include structural members formed with HDPE and a reinforcing member that acts as a strengthened core for the HDPE. The HDPE is preferably without cellular fiber content, such as wood fiber, and at least to the extent that any such content should not seriously impact resistance to moisture of the resulting structural member. Also preferably, the HDPE is without mineral fiber content, such as fiberglass, to the extent that the ability of the structural member can remain easily cut and/or drilled without tool damage. However, unless otherwise specified, any thermoplastic and/or thermoplastic composite materials are collectively herein referred to as simply “HDPE” or “thermoplastic,” and it is to be understood that reference herein to “HDPE” and “thermoplastic” includes other possible thermoplastics other than HDPE, as well as blends, composite/amended thermoplastic materials, and/or coated thermoplastic members, and further includes substantially virgin or recycled HDPE. Furthermore, other materials other than thermoplastics are within the scope of the invention. Thus, a structural member, such as an I-joist, that utilizes a non-thermoplastic (non-HDPE) material to form its flanges and/or webbing, is within the scope of the present invention.
- In alternative embodiments of the invention, I-
joist 70 is formed with a structure of HDPE, wherein either thewebbing 14 and/or any of the flanges, include one or more reinforcing or strengthening members. A strengtheningmember 75 is indicated by dotted detail inFIG. 6 , which may include, as for example, a fiberglass, metal, wood, or composite material. - Referring now to
FIGS. 7-8 , an I-joiststructural member 82 in accordance with embodiments of the present invention is shown. I-joist 82 may be understood to add elements to the basic structure of I-joist 70, and further includesflange reinforcing members flanges FIG. 8 shows an illustrative configuration which may serve for both reinforcingmembers flange reinforcing members flanges - The presence of
flange reinforcing members - In accordance with embodiments of the present invention,
flange reinforcing members flanges - Flange reinforcing members may take on a variety of shapes. Referring again to
FIG. 7 ,flange reinforcing members member 90, 91. - Corrugated reinforcing
member 90, 91 may include sharper or wider angles as compared to the example structure shown inFIGS. 7 and 8 , and may further include rounded corners and curved surfaces. Thus, it is to be understood that the shape of corrugated reinforcingmember 90, 91 shown inFIGS. 7 and 8 and is provided by way of illustration and not limitation. - Referring now to
FIG. 9 , another configuration offlange reinforcing members members FIG. 9 include a pair ofinward projections 98adjacent opening 102. In accordance with embodiments of the present invention, opening 102 is open towardwebbing 14, and is preferably substantially aligned with axis A-A ofwebbing 14. When placed inlower flange 78, substantially M-shaped reinforcingmember 95 is preferably inverted, as shown. - Referring now to
FIG. 10 , an I-joiststructural member 106 in accordance with embodiments of the present invention is shown. I-joist 106 adds to the structure of I-joist 70, and further includes at least one enclosedflange reinforcing member flanges - In the illustration of
FIG. 10 , each ofupper flange 74 andlower flange 78 includes a plurality of enclosedflange reinforcing members flange reinforcing member flange reinforcing member flange reinforcing member - As shown in
FIG. 10 , and in accordance with embodiments of the present invention, enclosedflange reinforcing members - As shown in
FIG. 10 , in one aspect of the present embodiment, the pair of enclosed flange reinforcing members positioned inupper flange 74, as well as the pair inlower flange 78, are spaced apart a distance “d” that is substantially the same as width “w” ofwebbing 14. However, separation distance d may be less than or greater than width w ofwebbing 14. - In accordance with preferred embodiments of the present invention, each of the enclosed flange reinforcing members is situated within
upper flange 74 orlower flange 78, wherein the material formingupper flange 74 orlower flange 78 completely surrounds the sides of each enclosed flange reinforcing members. Preferably, I-joist 106 includes an HDPE material that forms the upper and lower flanges, while the HDPE material completely surrounds each longitudinal side of the enclosed flange reinforcing members. - Referring now to
FIG. 11A , an I-joiststructural member 106′ is shown, wherein two adjacent enclosedflange reinforcing members upper flange 74 andlower flange 78, respectively.Flange reinforcing members upper flange 74 and may have a selected separation distance (if any), and a like configuration may be provided forflange reinforcing members means 111. - Referring now to
FIG. 11B , in accordance with embodiments of the present invention, reinforcingmember 71 is shown withinupper flange 74. However, it is to be understood that reinforcingmember 71 may be used inlower flange 78 of an I-joist, and may also be used in other structures, such as posts and beams. Reinforcingmember 71 includes a plurality ofrods 72 having a substantially circular cross section, wherein therods 72 are rigidly connected by across member 73. The reinforcingmember 71 is preferably formed of carbon fiber or a metal alloy, such as an aluminum alloy. Depending upon the loading conditions for the structural member, the reinforcing member may comprise solid orhollow rods 72, with a solid orhollow cross member 73. - In accordance with embodiments of the present invention, I-joists may include an upper flange having a reinforcing member, such as a corrugated reinforcing
member 90, and the lower flange may having a different type of reinforcing member, such as an enclosedflange reinforcing member 110. Accordingly, it is within the scope of the present invention that the upper and lower flanges may include different types of reinforcing members. Such configurations may be advantageous for certain design considerations, such as where the upper and lower flanges will experience different amounts and/or modes of loading. - Referring now to
FIG. 12 , in accordance with embodiments of the present invention, an I-joiststructural member 114 is shown that includes reinforcing wedges orgussets 118 as reinforcing members between outerupper flange 26 andwebbing 14. In addition,gusset reinforcing members 118 may also be used betweenwebbing 14 and outerlower flange 30.Gusset reinforcing members 118 may be formed as part of the outer flanges. - It will be appreciated by those skilled in the art that conventional wood or composite I-joists that are constructed by gluing the top and bottom flanges to the vertical center member are not weather-resistant, unlike HDPE weather-resistant embodiments of the present invention. An additional benefit of the present invention is that the configuration can be a plain or true I-system or a custom I-system.
- Such custom configuration may include strengtheners or deflection-reducing elements, such as having
gussets 118 supporting webbing and/or the upper and lower flanges, or having one ormore pins 136 mating the HDPE overlay and the reinforcing core, so as to further strengthen the resulting structural members. - Referring now to
FIG. 13 , a partial side elevation view of an I-joiststructural member 122 is shown that includes at least one, and more preferably, a plurality of vertical reinforcingmembers 126 positioned along the exterior ofwebbing 14. Vertical reinforcingmembers 126 increase stability, load capability and/or load transfer characteristics of I-joist. Vertical reinforcingmembers 126 are preferably spaced apart laterally and positioned between the bottom of outer upper flange 24 and the top of outerbottom flange 30. - Alternatively, vertical reinforcing
members 126 may be positioned between the bottom ofupper flange 18 and the top oflower flange 22, extending through the outerupper flange 26 and outerlower flange 30. Alternatively, for I-joists not having an outerupper flange 26 or an outerlower flange 30, vertical reinforcingmembers 126 may be placed betweenupper flange 74 andlower flange 78, as for example, in I-joists - Referring now to
FIG. 14 , in accordance with embodiments of the present invention, an I-joiststructural member 130 is shown that includes one or more knock-outs 134 inwebbing 14. Such knock-outs 134 are advantageous for passing conduits through the joist framing, such as for electrical power. - Redwood and treated hemlock/fir are often used for outside decking material because of their ability to withstand weathering better than other lumber products. Load to deflection tests have been conducted using I-joists according to the invention versus wood product that would be replaced therewith. Such testing demonstrated better performance of an I-joist of the present invention as against redwood and treated hemlock/fir. Therefore it will be appreciated that the present invention provides easy to configure and weather-resistant structural members with excellent load-bearing characteristics that enables improved load-bearing systems for a wide variety of applications.
- Referring now to
FIGS. 15A-15G , in accordance with embodiments of the present invention, additional illustrativestructural members 200 are shown by way of illustration and not by way of limitation of the invention. These members may serve as reinforcing configurations within the flanges for I-joists, beams, posts, studs, or the like in horizontal or vertical structural support systems, for a variety of purposes. An illustrative application includes structural columns and posts for supporting framing, such as to support dock or deck platforms, or such as otherwise may be used to support I-joists thereunder. -
Support members 200 include a core reinforcing member surrounded by a thermoplastic material, such as HDPE. The core reinforcing members are stiff or rigid and preferably hollow, and may be formed of a metal or metal alloy, such as an aluminum alloy, or may also be formed of carbon fiber. - The following configurations are described with respect to cross-sectional views. Referring to
FIG. 15A , a rectangular orsquare post 200 having a plurality of rectangularcore reinforcing members 204 is shown, wheremembers 204 are surrounded byouter layer 208 that includes HDPE. - Referring to
FIG. 15B , a rectangular orsquare post 200 is shown with a singlecore reinforcing member 204 having a rectangular cross section. Referring toFIG. 15C , a rectangular orsquare post 200 is shown with a singlecore reinforcing member 204 having a circular cross section. - Referring to
FIG. 15D , acircular post 200 is shown with a singlecore reinforcing member 204 having a circular cross section. Referring toFIG. 15E , acircular post 200 is shown with a singlecore reinforcing member 204 having a rectangular cross section. - Referring to
FIG. 15F , acircular post 200 is shown with acore reinforcing member 204 having a triangular cross section. Referring toFIG. 15G , acircular post 200 is shown with ancore reinforcing member 204 having a flattened oval cross section. Thus a variety of post configurations are possible, as are a variety of core reinforcing members, in practice of the invention. - During manufacture of the reinforcing members, or prior or during forming an I-joist, post, or beam, the reinforcing member may be textured to provide improved adhesion between the surface of the reinforcing member and the HDPE. Surface texturing is anticipated to provide better bonding between the thermoplastic material and the reinforcing member, and thus better structural performance.
- Referring again to
FIGS. 7-8 ,flange reinforcing members more apertures 88.Apertures 88 also provide continuity between the thermoplastic material, as for example HDPE, located above and below theflange reinforcing members - It will be further appreciated that surfaces of
flange reinforcing members flange reinforcing members core reinforcing member 204, and the like, may include a textured, scarified, and/or roughed surface and which may also include projections or indentations as well asapertures 88. An example of this surface treatment is generally shown inFIG. 5 asdetails 66. - Referring now to
FIG. 16 , a structural reinforcingmember 300 is provided that includes a plurality of arms extending from acentral core 304. In accordance with illustrative embodiments of the present invention, structural reinforcingmember 300 includes four arms, including afirst arm 308, asecond arm 312, athird arm 316, and afourth arm 320. Thefirst arm 308 is preferably situated substantially oppositethird arm 316, or between about 160 to 200 degrees fromthird arm 316, and more preferably, about 180 degrees fromthird arm 316. Similarly,second arm 312 is also preferably situated substantially oppositefourth arm 320, or between about 160 to 200 degrees fromfourth arm 320, and more preferably, about 180 degrees fromfourth arm 320. In addition,first arm 308 is separated fromsecond arm 312 by between about 45 to 90 degrees, and more preferably, by between about 55 to 75 degrees, and more preferably yet, by between about 68 degrees. Similarly,third arm 316 is separated fromfourth arm 320 by between about 45 to 90 degrees, and more preferably, by between about 55 to 75 degrees, and more preferably yet, by between about 68 degrees. A structural reinforcing member may have more than four arms and is considered within the scope of the present invention. As for example and not intending to limit the scope of the invention, a reinforcing member may comprise six arms. - Structural reinforcing
member 300 is encased within HDPEstructural member 328 and preferably includes a metal alloy, such as an aluminum alloy, or carbon fiber. In accordance with several embodiments of the present invention,central core 304 is preferably hollow. Structural reinforcingmember 300 preferably extends the entire longitudinal length L ofstructural member 328. - Referring now to
FIG. 17 , a modified structural reinforcingmember 300′ is shown, wherein structural reinforcingmember 300′ includes an internal reinforcingcore 332. Reinforcingcore 332 adds additional strength to structural reinforcingmember 300′, and allowsstructural member 328′ including structural reinforcingmember 300′ to be used in higher load types of applications, but without the extra weight of a solid core addition. - As shown in
FIG. 17 , reinforcingcore 332 appears as a cross-shaped member. However, other shaped reinforcing cores are within the scope of the present invention. As for example, reinforcing core may include a substantially square, circular or diamond shape in cross section. - Referring still to
FIGS. 16 and 17 , and in accordance with embodiments of the invention, the exterior surface of structural reinforcingmembers members exterior rib 336 may be provided at theexterior intersection 340 betweenarms members Ribs 336 preferably extend the longitudinal length L of structural reinforcingmembers - Still referring to
FIGS. 16 and 17 , in accordance with embodiments of the present invention,ribs 336 may further include fully penetrating or partially hollowed out depressions ordivots 344.Divots 344 are preferably spaced apart along the longitudinal length ofribs 336.Divots 344 serve to furtheranchor reinforcing member Divots 344 assist in limiting or removing sliding tendencies between the HDPE and reinforcingmembers structural members member apertures 88 that act as openings for receiving at least some HDPE when the HDPE is extruded around the reinforcingmember divots 344, theapertures 88 assist in limiting or removing sliding tendencies between the HDPE and reinforcingmembers structural members - Referring now to
FIGS. 18-20 , end elevation views of structural reinforcingmembers 300′ are shown, whereinarms shapes 348, such as prongs or lobes. For the reinforcing members shown inFIGS. 18-20 , reinforcingcores 332 may be omitted if a hollowstructural member 300 without reinforcingcores 332 is desired. Reinforcingmembers - In practice of an embodiment of the invention, structural reinforcing
members FIG. 21 illustrates an embodiment of the present invention, wherein I-joist 350 includesflange members joist 350 the reinforcingmember first arm 308 andsecond arm 312 is transverse to axis A-A of the I-joist 350, and more preferably, bisector “b1-2” is substantially perpendicular to axis A-A of I-joist 350. Similarly, bisector “b3-4” of the angle “α3-4” betweenthird arm 316 andfourth arm 320 is transverse to axis A-A of the I-joist 350, and more preferably, bisector “b3-4” is substantially perpendicular to axis A-A of I-joist 350. I-joist 350 is anticipated to preferably be oriented such that a compression load or force “F” applied to I-joist 350 is substantially parallel to axis A-A of I-joist 350. - The configuration of the reinforcing
member joist 350. This is achieved under loading conditions when theupper arms lower arms first arm 308 and thesecond arm 312 tend to converge toward each other compressing the HDPE between them together and thereby further locking the reinforcingmember fourth arm 320 andthird arm 316 tend to converge toward each other compressing the HDPE between them together and thereby further locking the reinforcingmember ribs 336 and associateddivots 344, whether partially or fully penetrating, keep the HDPE from traversing along the longitudinal axis of the reinforcingmember - Referring now to
FIG. 22 , in accordance with embodiments of the present invention, an I-joist 352 is shown that comprises a web andflange reinforcing member 354. The web andflange reinforcing member 354 preferably is formed of carbon fiber or a metal alloy, such as an aluminum alloy. The web andflange reinforcing member 354 preferably comprises an assembled, integral structure that includeswebbing 356 that is connected or formed integrally with reinforcingflange members flange members members core 332. In addition, thewebbing 356 may be solid and combined with hollow reinforcing members. For a web andflange reinforcing member 354 made of carbon fiber, thewebbing 356 is preferably thinner in width w than a structurallyequivalent webbing 14 that is made of HDPE. As for example, thewebbing 356 may be about 3/16 of an inch in width. In accordance with embodiments of the present invention, to form the I-joist 352, HDPE is extruded to the exterior of reinforcingflange members flange reinforcing member 354. - Referring now to
FIG. 23 , an end-on side elevation view of arim joist 362 in accordance with embodiments of the present invention is shown. Therim joist 362 includes the web andflange reinforcing member 354 as described above for I-joist 352, and further comprises a substantially rectangular shapedouter member 364 encompassing the web andflange reinforcing member 354. - Referring now to
FIG. 24 , a side elevation view of only the web andflange reinforcing member 354 is shown. In accordance with embodiments of the present invention, theweb 356 of the web andflange reinforcing member 354 may includeholes 366 spaced apart along its longitudinal length. - Combining HDPE with a metal alloy, such as an aluminum alloy, or carbon fiber, in the configurations shown and described herein provides functionality by increasing loading strength. Under compression or tension, the integral configuration of the structural members, flanges and the like, serves to resist movement from either, thereby improving load ratings. Hollow cores enable achieving structurally sound members with some reduction of weight.
- In accordance with embodiments of the present invention, at least one method of manufacture is also provided, the method comprising a unique process. As one example, the method of manufacture may comprise a dual extrusion in-line fabrication process. It will be appreciated that the various structural assemblies are described herein which generally may be referred to as structural members or load members, and are preferably formed in a sequence of separate steps. As an illustration, for example,
web member 13 andflanges joist 10. Likewise,web member 13,channel reinforcing members flanges joist 60. As a further example, any of reinforcingmembers structural member member structural member - In accordance with another embodiment of the present invention, an illustrative method of manufacturing a structural support member having a rated deflection loading includes: (a) preparing a structural reinforcing member of at least length L for bonded integration into a structural support member of at least length L; (b) forming a structural support member preform by feeding the structural reinforcing member into a thermoplastic extruder and extruding the structural reinforcing member with a thermoplastic, wherein the thermoplastic is bonded to the surface of the structural reinforcing member along the length of at least L; and (c) controlledly cooling the extrusion-formed structural support member preform wherein the thermoplastic is bonded to the structural reinforcing member along the length of at least L and wherein the bonded thermoplastic and structural reinforcing member share the loading of the structural support member without separating along the at least length L when the structural support member is loaded to the rated deflection loading.
- Practice of the invention may further include preparing the structural reinforcing member, to include forming an aluminum alloy extrusion with a non-uniform surface, the surface extending a length of at least L. The method may further include forming an aluminum alloy with a non-uniform surface that includes providing surface attributes that improve the bonding of the thermoplastic (or thermoplastic composites, such as amended HDPE) to the structural reinforcing member. The method may further include preparing the structural reinforcing member to include forming an aluminum alloy extrusion with a non-uniform surface, the surface extending a length of at least L. Furthermore, the method may include preparing the structural reinforcing member to include extruding the structural reinforcing member and adjusting its temperature by cooling.
-
FIG. 25 shows an illustrative method 400 for forming a structural member of the invention, including: (a) the step 404 of selecting the structural member, including selecting a thermoplastic material, and a reinforcing member shape and material type; (b) the step 408 of preparing to manufacture the structural member, including preparation of resins and reinforcing materials; (c) the step 412 of extruding the reinforcing member, such as extruding an aluminum alloy reinforcing member; (d) the step 416 of modifying, if appropriate, the reinforcing member, such as by adding partially or fully penetrating divots or apertures, scarifying at least a portion of the surface of the reinforcing member, and/or otherwise providing texturizing features to the reinforcing member that were not otherwise generated when the reinforcing member was extruded; (e) the step 420 of cooling the reinforcing member (which may occur before step (d) depending upon the materials used and the nature of the modifications performed in step 416); (f) the optional step 424 of adding any adhesives or bonding agents to at least a portion of the surface of the reinforcing member (such as may be necessary of a carbon fiber reinforcing member is used in combination with HDPE outer member); (g) the step 428 of feeding the reinforcing member, such as the aluminum alloy reinforcing member into the HDPE extruder; (h) the step 432 of extruding the HDPE around the reinforcing member; and (i) the step 436 of cooling the structural member comprising the HDPE and reinforcing member, where such cooling may be performed in a controlled fashion. - In one embodiment, at least some of
steps 412 through 436 are continuous, wherein a reinforcing member is extruded to specification, cooled and texturized (if necessary), and then fed into an HDPE extruder, extruded with HDPE, and then cooled to form the desired structural member. Thestep 436 of cooling the extruded structural member may accommodate for complexities in cooling the extruded structural member having diverse materials, such as having a HDPE over an aluminum or carbon fiber reinforcing member. This dual in-line fabrication extrusion method has the advantage of providing all necessary opportunity for engineered control of a continuous manufacture process in one location. U.S. Patent Application Publication US 2005/0108983 A1 discloses a method of forming a reinforced extruded composite structural member, and such publication is incorporated herein by reference in its entirety. - To assist in the understanding of the present invention the following list of components and associated numbering found in the drawings is provided herein:
Number Component 10 I-joist 13 web member 14 webbing 18 upper flange 22 lower flange 26 upper outer flange 27 upper flange assembly 29 lower flange assembly 30 lower outer flange 34 receptacle (of the upper outer flange 26) 38 key (of the webbing 14 and upper flange 18) 39 locking mechanism 42 key (of the webbing 14 and lower flange 22) 43 locking mechanism 46 receptacle (of the lower outer flange 30) 60 I-joist 64 channel reinforcing member 65 channel reinforcing member 66 details/surface texturing 68 opening 70 I-joist 71 reinforcing member 72 rods 73 cross member 74 upper flange 75 strengthening member 78 lower flange 82 I-joist 86 flange reinforcing member 87 flange reinforcing member 88 aperture 90 corrugated reinforcing member 91 corrugated reinforcing member 94 M-shaped reinforcing member 95 M-shaped reinforcing member 98 inward projections (of M-shaped reinforcing member 94) 106 I-joist 106′ I-joist 109 enclosed flange reinforcing member 110 enclosed flange reinforcing member 111 connecting means 114 I-joist 118 gusset reinforcing member 122 I-joist 126 vertical reinforcing member 130 I-joist 134 knock-outs 136 pins 200 structural member (or post) 204 core reinforcing member (of post 200) 208 outer layer (of post 200) 300 structural reinforcing member 300′ structural reinforcing member 304 central region (of structural reinforcing member 300 or 300′) 308 first arm (of structural reinforcing member 300 or 300′) 312 second arm (of structural reinforcing member 300 or 300′) 316 third arm (of structural reinforcing member 300 or 300′) 320 fourth arm (of structural reinforcing member 300 or 300′) 328 structural member (with structural reinforcing member 300) 328′ structural member (with structural reinforcing member 300′) 332 reinforcing core (of structural reinforcing member 300′) 336 rib (of structural reinforcing member 300 or 300′) 340 exterior intersection (between the arms 308, 312, 316, 320) 344 divot 348 end shape (of arms 308, 312, 316, 320) 350 I-joist 352 I-joist 354 web and flange reinforcing member 356 webbing 358 reinforcing flange member 360 reinforcing flange member 362 rim joist 364 outer member 366 holes 400 method of manufacturing 404 select (reinforcing member specifics and outer material specifics) 408 prepare (reinforcing member and outer HDPE) 412 extruding alloy (or other reinforcing member) 416 rib/scarify/texturize alloy (or other reinforcing member) 420 cool alloy (or other reinforcing member) 424 apply adhesive (optional depending upon material type of reinforcing member) 428 feed alloy (or other reinforcing member) 432 extrude HDPE around alloy (or other reinforcing member) 436 cool HDPE A—A axis (of webbing 14 or joist) α1-2 angle between first arm 308 and second arm 312 α3-4 angle between third arm 316 and fourth arm 320 b1-2 bisector of the angle α1-2 b3-4 bisector of the angle α3-4 F force L longitudinal length d separation distance (between reinforcing members) w width (of webbing 14) - The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.
- The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit Invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
- Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
Claims (33)
1. A method of manufacturing a structural support member having a rated deflection loading, comprising:
preparing a structural reinforcing member for bonded integration into a structural support member, the structural reinforcing member comprising a plurality of opposing arms;
forming a structural support member by feeding the structural reinforcing member into a thermoplastic extruder and covering the structural reinforcing member with a thermoplastic, wherein the thermoplastic is bonded to at least a portion of an exterior surface of the structural reinforcing member.
2. The method of claim 1 , further comprising cooling the extrusion-formed structural support member wherein the bonded thermoplastic and structural reinforcing member share the loading of the structural support member without separating when the structural support member is loaded to the rated deflection loading.
3. The method of claim 1 , wherein said preparing the structural reinforcing member includes forming an aluminum alloy extrusion with a non-uniform surface.
4. The method of claim 3 , wherein said forming the aluminum alloy with a non-uniform surface includes providing surface attributes that improve bonding of the thermoplastic to the structural reinforcing member.
5. The method of claim 4 , wherein the providing surface attributes includes adding at least one of a divot, aperture, ribbing, scarified surface and texturing to the surface of the structural support member.
6. The method of claim 1 , wherein said preparing the structural reinforcing member further includes extruding the structural reinforcing member and adjusting its temperature by cooling.
7. The method of claim 1 , wherein said structural reinforcing member comprises at least one of a metal alloy, aluminum, aluminum alloy, and carbon fiber.
8. The method of claim 1 , wherein said plurality of arms comprises at least four arms.
9. The method of claim 8 , wherein a bisector of an angle between a first arm and a second arm of the plurality of arms is substantially perpendicular to an axis of the structural support member, and wherein the structural support member is configured for orienting so that a compression force applied to the structural support member is substantially parallel to said axis of the structural support member.
10. The method of claim 1 , wherein said thermoplastic comprises HDPE.
11. The method of claim 1 , wherein said structural support member is selected from the group consisting of a beam, a post, a column, at least a portion of an I-joist, a rim joist, and at least a portion of a truss.
12. A method of manufacturing a structural member, comprising:
preparing a structural reinforcing member having a longitudinal length L and a plurality of substantially hollow arms; and
extruding a resin around the structural reinforcing member along substantially the entire longitudinal length L of the structural reinforcing member to form the structural member.
13. The method of claim 12 , wherein said preparing the structural reinforcing member includes forming an aluminum alloy extrusion with a non-uniform surface.
14. The method of claim 13 , wherein said forming an aluminum alloy includes providing surface attributes that improve bonding of the resin to the structural reinforcing member.
15. The method of claim 14 , wherein the providing surface attributes includes adding at least one of a divot, aperture, ribbing, scarified surface and texturing to a surface of the structural member.
16. The method of claim 12 , wherein said preparing the structural reinforcing member further includes extruding the structural reinforcing member and adjusting its temperature by cooling.
17. The method of claim 12 , wherein said structural reinforcing member comprises at least one of a metal alloy, aluminum, aluminum alloy, and carbon fiber.
18. The method of claim 12 , wherein said plurality of arms comprises at least four arms including a first arm substantially opposite a third arm, and a second arm substantially opposite a fourth arm.
19. The method of claim 18 , wherein a bisector of an angle between the first arm and the second arm is substantially perpendicular to an axis of the structural member, and wherein the structural member is configured for orienting so that a compression force applied to the structural member is substantially parallel to the axis of the structural member.
20. The method of claim 12 , wherein said resin comprises HDPE.
21. The method of claim 12 , wherein said structural member is selected from the group consisting of a beam, a post, a column, at least a portion of an I-joist, a rim joist, and at least a portion of a truss.
22. A method of forming a structural member adapted for use in a load-bearing assembly, comprising:
preparing a structural reinforcing member from a first material having a longitudinal length L and a plurality of arms extending outwardly therefrom;
modifying the structural reinforcing member including adding at least one of a divot, aperture, ribbing, scarified surface and texturing to a surface of the structural reinforcing member; and
extruding a second material around the longitudinal length L of the structural reinforcing member and said plurality of arms to form a structural member;
wherein the structural member is configured for use in construction of the load-bearing assembly.
23. The method of claim 22 , wherein the second material is bonded to at least a portion of the surface of the structural reinforcing member.
24. The method of claim 22 , wherein said preparing the structural reinforcing member includes forming an aluminum alloy extrusion.
25. The method of claim 22 , wherein said preparing the structural reinforcing member further includes extruding the structural reinforcing member and adjusting its temperature by cooling.
26. The method of claim 22 , wherein said first material comprises at least one of a metal alloy, aluminum, aluminum alloy, and carbon fiber.
27. The method of claim 22 , wherein said plurality of arms comprises at least four arms including a first arm substantially opposite a third arm, and a second arm substantially opposite a fourth arm.
28. The method of claim 27 , wherein a bisector of an angle between the first arm and the second arm is substantially perpendicular to an axis of the structural member, and wherein the structural member is configured for orienting so that a compression force applied to the structural member is substantially parallel to the axis of the structural member.
29. The method of claim 22 , wherein said structural member is selected from the group consisting of a beam, a post, a column, at least a portion of an I-joist, a rim joist, and at least a portion of a truss.
30. The method of claim 22 , further comprising using the structural member to construct the load-bearing assembly, the load bearing assembly comprising at least one an indoor and outdoor support structure.
31. The method of claim 22 , wherein said second material comprises a resin.
32. The method of claim 22 , wherein said second material comprises a thermoplastic.
33. The method of claim 22 , wherein said second material comprises HDPE.
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2007
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2008
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2011
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US6701690B2 (en) * | 2001-07-17 | 2004-03-09 | Guildo Deschenes | I-shaped wooden beam |
US6708459B2 (en) * | 2001-07-18 | 2004-03-23 | Gcg Holdings Ltd. | Sheet metal stud and composite construction panel and method |
US6672026B2 (en) * | 2002-05-03 | 2004-01-06 | Creative Pultrusions, Inc. | Pultruded I-bar with clip fittings enabling automated grating panel assembly |
US6844040B2 (en) * | 2002-10-01 | 2005-01-18 | Arunas Antanas Pabedinskas | Reinforced composite structural members |
US20050108983A1 (en) * | 2003-05-30 | 2005-05-26 | Peter Simko | Reinforced composite structural members and methods of making the same |
US20060032182A1 (en) * | 2004-08-02 | 2006-02-16 | Barry Carlson | Engineered structural members and methods for constructing same |
Cited By (2)
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US20130160398A1 (en) * | 2010-03-19 | 2013-06-27 | Weihong Yang | Composite i-beam member |
US8910455B2 (en) * | 2010-03-19 | 2014-12-16 | Weihong Yang | Composite I-beam member |
Also Published As
Publication number | Publication date |
---|---|
US20060032182A1 (en) | 2006-02-16 |
WO2006017552A3 (en) | 2007-05-10 |
US20070193199A1 (en) | 2007-08-23 |
CA2575746C (en) | 2011-03-01 |
EP1778929A2 (en) | 2007-05-02 |
US7213379B2 (en) | 2007-05-08 |
EP1778929A4 (en) | 2008-12-31 |
WO2006017552A2 (en) | 2006-02-16 |
US8322037B2 (en) | 2012-12-04 |
US7882679B2 (en) | 2011-02-08 |
HK1111746A1 (en) | 2008-08-15 |
CN101031696A (en) | 2007-09-05 |
US20110179647A1 (en) | 2011-07-28 |
CA2575746A1 (en) | 2006-02-16 |
CN101031696B (en) | 2010-05-05 |
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