Reinforced Structural Element for Screen Enclosures

Abstract

A product, system and method for reinforcing structural members is provided. The invention includes an elongated beam having a plurality of walls, each of the plurality of walls forming an internal cavity including an interior surface and an exterior surface; a reinforcing material preferably a flowable, strong, conglomerate construction material that hardens and gains strength when cured, such as a cementious building material (e.g., cementious grout or foam), disposed within the internal cavity, whereby the cured reinforcing material and walls form a strong, composite structural member. The invention further comprises a layer of sealant and/or protectant applied on the interior surface of the walls of the beam to prevent interaction between the reinforcing material and the walls (e.g. aluminum or metal or alloy). The invention further comprises one or more reinforcing rods (e.g. rebar) extending from a slab into the internal cavity.

Description

FIELD OF THE INVENTION

The present invention relates to methods and products for reinforced structural elements. More particularly this invention concerns reinforced structural elements comprising metal beams and columns filled with cementious or form reinforcing material used in screen enclosures and the like, including the process of making and installing same.

BACKGROUND OF THE INVENTION

Aluminum framing components, such as those used in the construction of pool, patio and porch enclosures, are generally comprised of hollow aluminum extrusions which are fastened together. The hollow extrusions used today have top and bottom walls and two sidewalls. They are used in screen enclosures as beams, purlins, rails, upright columns and the like. Generally, the larger the area of the enclosure, the bigger, stronger and heavier the extrusions must be in order to meet the design and structural loads and wind pressure resistance standards required by building codes.

The new building codes require aluminum enclosures to be built to withstand higher wind speeds than ever before and significantly higher design pressures and structural loads than in the past. The result is an enclosure that must consist of heavier and larger beam members to meet the same span and height criteria than was previously necessary under prior building codes.

Inasmuch as most of the screen enclosures used today are constructed from aluminum, and specifically, extruded aluminum, one of the most contemplated methods for use in designing such frames to meet wind load requirements in high wind prone areas, has been to increase column and beam size and/or decrease structural member spacing of the aluminum enclosures themselves, which increases the overall cost of the product.

U.S. Pat. No. 6,430,888 discloses aluminum framing components and component systems for pool, patio and glass enclosures and the like. Other patents disclosing reinforced structural components include: U.S. Pat. Nos. 6,826,885; 6,701,684; 6,341,467; 5,966,894; 5,942,173; 5,921,053; 5,758,456; 5,471,809; 4,978,562; 4,944,545; and 4,852,322, each of which is incorporated herein by reference.

However, none of the systems disclosed in any of these patents efficiently and inexpensively reinforce structural members. It is as a result of this serious shortcoming in the field of reinforced structural members that the present invention is being proposed.

All patents, patent applications, provisional applications, and publications referred to or cited herein, or from which a claim for benefit of priority has been made, are incorporated herein by reference in their entirety to the extent they are not inconsistent with the explicit teachings of this specification.

SUMMARY OF THE INVENTION

The present invention comprises a system and method of providing reinforced structural members. In an embodiment, the invention provides a structural member for use in forming a frame for an architectural structure, such as a screen enclosure, comprising: an elongated beam having a plurality of walls, each of said plurality of walls forming an internal cavity including an interior surface and an exterior surface; a reinforcing material preferably a flowable, strong, conglomerate construction material that hardens and gains strength when cured, such as a cementious building material (e.g., cementious grout) or foam, disposed within the internal cavity, whereby the cured reinforcing material and walls form a strong, composite structural member. The invention further comprises a layer of sealant and/or protectant applied on the interior surface of the walls of the beam to prevent interaction between the reinforcing material (e.g., concrete, cement, cementious grout) and the walls (e.g. aluminum or metal or alloy). The invention further comprises one or more reinforcing rods (e.g. rebar) extending from a slab or footer into the internal cavity. The rods may be omitted with the use of foam but are preferred with the use of concrete, cement, or cementious grout.

As a method of reinforcing structural members, the invention comprises (1) inserting and securing one or more reinforcing rods into a slab/footer upon which the structural member is being placed, (2) positioning an elongated beam/column having a plurality of walls, each of said plurality of walls forming an internal cavity over the reinforcing rod, (3) filling the internal cavity with reinforcing material (such as cementious grout or foam). The rods may be omitted with the use of foam but are preferred with the use of concrete, cement, or cementious grout. As an additional step, a protective coating can be applied to the internal cavity of the beam/column to prevent or inhibit a reaction between the reinforcing material and the walls (e.g., prevent concrete and aluminum interaction). For beams/columns already in place, the invention comprises the steps of: (1) accessing the internal cavity of the elongated beam/column such as by cutting an access hole into the side of the beam and/or separating the two sections of the beam/column, (2) drilling holes in the slab/footer where the beam/column and slab/footer meet, (3) inserting and securing one or more reinforcing rods into a slab/footer such that the reinforcing rod extends into the cavity of the beam/column, (4) filling the internal cavity with reinforcing material (such as cementious grout or foam). As an additional step, a protective coating can be applied to the internal cavity of the beam to prevent or inhibit a reaction between the reinforcing material and the walls.

The present invention provides many advantages. For example, use of the system will allow screen enclosures to be built with longer spans and taller walls using smaller dimension extrusions and still meet current code requirements. The system is more cost effective than the widely accepted method of increasing column and beam sizes and/or decreasing column and beam spacing to meet code requirements.

It is, therefore, a principal object of this invention to provide a system and apparatus for reinforcing structural members.

These advantages and other objects will be apparent to those skilled in the art when viewed in connection with the following description of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a schematic perspective view of one form of enclosure comprised of a plurality of aluminum framing components and component systems.

FIG. 2 illustrates an extruded beam of the prior art.

FIG. 3 illustrates a reinforced extruded beam/column of the present invention.

FIG. 4 illustrates sample rebar forms for use with the invention.

FIG. 5 illustrates a first example reinforced beam and rebar positioning of the present invention when used for retrofitting with an access hole.

FIG. 6 illustrates a second example reinforced beam and rebar positioning of the present invention when used for retrofitting.

DETAILED DESCRIPTION

Referring now in detail to the drawings, and initially to FIG. 1, there is schematically shown one form of pool enclosure 1 constructed of various aluminum framing components including roof beams 2, shown in solid lines in FIG. 1, extending from an existing structure 3 to primary upright columns 4, at the front wall 5 of the enclosure. In addition, the enclosure 1 includes numerous hollow aluminum extrusions 6, shown in dashed lines, used for top rails 7, chair rails 8, corner posts 9, side wall uprights 10 and purlins 11 to transfer loads and maintain spacing between the primary structural members 2 and 4. Extending along the bottom of the side walls 15 and front wall 5 of the enclosure 1 as well as beneath the front wall purlins 11 and alongside the corner posts 9 are 1×2 open back aluminum extrusions 16, shown in longer dashed lines in FIG. 1, for use in attaching screens at these points.

The particular enclosure 1 shown in FIG. 1 has a dome shape roof 17. However, it will be appreciated that the roof may be of other shapes including mansard, gable, flat, gable/hip and shed. Moreover, the enclosure may be of other types including patio and glass enclosures and the like.

Extruded beams/columns (hereinafter collectively referred to as “beams” for simplicity, such as those used for supporting screening material around patios, pools, porches, etc, are well known in the art and have been manufactured in a wide variety of shapes. An example of one such beam is shown in FIG. 2. The beam 20 is constructed of a pair of “C” shaped halves 22 and 24, and are connected along respective upper and lower serrated interfaces 32, 34 forming an interior cavity. Such beams 20 are provided in whatever length is appropriate to the design of the structure. Beam halves 22 and 24 can be connected by any conventional means, such as by use of a sheet metal screw, rivet, or other fastener (not shown). Channels “c” (spline grooves) are provided, which are used to receive the beaded edge (not shown) of a section of screen.

Such beams, being structural members of a screen enclosure, are subject to forces brought on by gravity, wind, loads and the like. With the ever increasing size of today's screen enclosures and other structures which utilize similar structural members, and with the increasingly stringent building code specifications for such members, it is desirable to provide an apparatus, system and method for inexpensively and efficiently reinforcing such beams but only in the areas where reinforcement is called for.

Referring now to FIG. 3, there is disclosed a modified beam 30 in accordance with the instant invention. Beam 30, like beam 20 of FIG. 2, is comprised of a pair of halves 22, 24, which meet along serrated interfaces 32, 34, and which can be fastened together using any suitable means, such as coated stell screws inserted through the serrated surfaces 32, 34. Channels “C” are provided for the reasons specified in connection with FIG. 2. The improvement provided by this invention is found by filling the beam 30 with a reinforcing material 50 such as cementious grout or foam 50. In order to prevent a reaction of the reinforcing material, the interior surface of beam 30 is coated with a sealant or protectant.

Specifically, the invention comprises an elongated beam having a plurality of walls, each of said plurality of walls forming an internal cavity including an interior surface and an exterior surface. A reinforcing material 50 preferably a flowable, strong, conglomerate construction material that hardens and gains strength when cured, such as a cementious building material (e.g., cementious grout) or foam, is disposed within the internal cavity, whereby the cured reinforcing material and walls form a strong, composite structural member. The invention further comprises a layer of sealant and/or protectant applied on the interior surface of the walls of the beam to prevent interaction between the reinforcing material (e.g., concrete, cement, cementious grout) and the walls (e.g. aluminum or metal or alloy). The invention further comprises one or more reinforcing rods (e.g. rebar 52) extending from a slab/footer (hereinafter collectively “slab” for simplicity) into the internal cavity.

As a method of reinforcing structural members, the invention generally comprises (1) inserting one or more reinforcing rods into a slab upon which the structural member is being placed, (2) positioning an elongated beam having a plurality of walls, each of said plurality of walls forming an internal cavity over the reinforcing rod, (3) filling the internal cavity with reinforcing material (such as cementious grout) or foam. As an additional step, a protective coating can be applied to the internal cavity of the beam to prevent or inhibit a reaction between the reinforcing material and the walls (e.g., prevent concrete and aluminum interaction).

More specifically, during installation of a new structure (e.g., screen enclosure or pool enclosure), the preferred detailed steps of the invention comprise the following (ordering of which may be altered as known in the art): Prior to installation, the interior wall of each beam 30 (column) is coated with an appropriate sealant to prevent interaction (e.g., concrete and aluminum interaction). It may be applied as known in the art, for example, with a spray wand inserted into the internal cavity to spray the sealant. Next, the deck/slab/footer is prepared by drilling the appropriate size and depth holes in the slab sufficient to receive reinforcement rods (rebar) 52.

As shown in FIG. 4, a variety of shape/size/number reinforcement rods may be used with the present invention (52a, 52b, 52c). In one embodiment, one or more U-shaped #5 reinforcement rods are used. In another embodiment, two (or more) upright reinforcement rods/rebar are used. In still another embodiment, one or more “L” shaped rods/rebar are used. The shape, size, position, and number of the reinforcement rods is a matter of design choice and, thus, may be chosen to form the desired function of reinforcement. Moreover, the size, depth, width, spacing, and height of the rebar are a matter of design choice and structural engineering requirements as appropriate.

The ends of the rebar are inserted into appropriately spaced holes in the slab. The rebar may be positioned, for example, at a minimum of 1″ from the walls and from each other. For example, the rebar may be set approximately 5 inches (as a preferred minimum) into the slab (the preferred insertion depth may be marked on the rebar with paint or a depth plate). The rebar may then extend upwards to a preferred maximum distance of 5 inches from the top of the beam/column. A further method of bonding may include using a short length of wire (e.g., 14 gauge) with a washer welded or attached with ground lug to rebar and attached to the wall of the beam/column with a screw or the like. Adhesive may be used for the slab/rebar connection as known in the art, such as ultrabond high strength anchoring and doweling epoxy meeting ASTM standard C-881 or equal).

Once the rebar 52 is set in accordance with any cure time, the bottom end of the beam/column 30 is positioned over the rebar 52 so that the rebar extends into the internal cavity of the beam. The beam 30 is then filled from the top (or other access point if necessary) with reinforcing material 50, preferably a form of cementious grout or foam that has an appropriate strength upon curing. For example, a minimum strength preferably is 3000 PSI at 28 days for cementious grout. The beams/columns may then be connected to the eve rails through a lintel aluminum shape that may also be coated.

For beams already in place, the invention as illustrated by example in FIGS. 5-6 comprises the steps of: (1) accessing the internal cavity of the elongated beam such as by cutting an access opening into the side of the beam 30 or separating the “C” shaped halves, (2) drilling holes in the slab where the beam and slab meet, (3) inserting one or more reinforcing rods 52 into a slab such that the reinforcing rod extends into the cavity of the beam and then closing the access point and/or refastening the “C” shaped halves, (4) filling the internal cavity with reinforcing material 50 up to a predetermined amount or height (such as with cementious grout or foam). As an additional step, a protective coating can be applied to the internal cavity of the beam prior to filling to prevent or inhibit a reaction between the reinforcing material and the walls.

More specifically, as shown in FIG. 5, to retrofit an existing structure to have reinforced structural elements, one method of the invention comprises the following steps (ordering of which may be altered as known in the art): First, an access opening 60 is made at or near the bottom of the beam/column 20 in order to install the reinforcing rod(s) (rebar) 52. Preferably, the interior cavity is accessed by cutting a small opening in the side of the beam/column 20 of sufficient size to be able to drill one or more holes 62 in the slab 64 and install the rebar 52. Since the opening 60 will likely be along the side of the column 20, the drill will be at an angle of about 15 degrees when it drills into the slab 64. Accordingly, the rebar 52 may be shaped to match the angle of the drill hole and extend into the cavity of the beam/column 20. In a preferred embodiment, an L-shaped #5 rebar at about 15 degrees is used (See 52c of FIG. 4). The end of the rebar 52 is inserted into the angled hole 62 in the slab 64. Adhesive is used for the slab/rebar connection as known in the art. The size, depth, width, spacing, and height of the rebar are a matter of design choice and structural engineering requirements as appropriate. The angle of the hole preferably matches the angle of the rebar and is not necessarily set at 15 degrees. The opening 60 in the wall of the beam/column is then closed. Next, the interior walls of each beam (column) is coated with an appropriate sealant to prevent interaction (e.g., concrete and aluminum interaction). It may be applied as known in the art, for example, with a spray wand inserted into the internal cavity (preferably from the top) to spray the sealant. Once the rebar 52 is set in accordance with cure time, the beam 20 is then filled from a top access point (or other access point if necessary) with reinforcing material 50 up to a predetermined amount, preferably a form of cementious grout that has an appropriate strength upon curing or foam. For example, a minimum strength preferably is 3000 PSI at 28 days for cement. In an alternate embodiment, the interior walls of the beam may be pre-coated with a coating/sealant/protectant prior to assembly and/or installation.

Another retrofitting method, as shown in FIG. 6, comprises the following steps (ordering of which may be altered as known in the art): First, the “C” shaped halves 22, 24 of the beam/column 20 are separated in order to install the reinforcing rod(s) (rebar) 52. In one embodiment, two (or more) upright reinforcing rods are used (See 52a of FIG. 4). Holes 62 are drilled in the slab 64 for the rebar 52. The end of the rebar 52 is inserted into the hole 62 in the slab. Adhesive may be used for the slab/rebar connection as known in the art. The size, depth, width, spacing, and height of the rebar are a matter of design choice and structural engineering requirements as appropriate. The “C” shaped halves 22, 24 are then re-attached. Next, the interior wall of each beam (column) 20 is coated with an appropriate sealant to prevent interaction (e.g., concrete and aluminum interaction). It may be applied as known in the art, for example, with a spray wand inserted into the internal cavity (preferably from the top) to spray the sealant. Once the rebar 52 is set in accordance with cure time, the beam 20 is then filled from a top access point (or other access point if necessary) with reinforcing material 50 up to a predetermined amount or height, preferably a form of cementious grout or foam that has an appropriate strength upon curing. For example, a minimum strength preferably is 3000 PSI at 28 days for cementious grout. In an alternate embodiment, the interior walls of the beam may be pre-coated with a coating/sealant/protectant prior to assembly and/or installation.

Any suitable coating/sealant/protectant may be used, such as a variety of paints, clear urethanes, and other suitable coatings. The coating materials may be either organic, such as paint, or inorganic. Inorganic coatings, such as anodized finishes, convert the outer layer of aluminum to aluminum oxide, producing an extremely durable surface. Applying a clear (organic) coating can further protect the anodized surface. High-performance coatings (fluorocarbons, siliconized acrylics, siliconized polyesters) may be used. One or more coats of bituminous paint or zinc chromate primer may also be used to provide separation of the aluminum from cement-based products. In a specific example, an alkali-resistant coating (e.g., heavy bodied bituminous paint) is used.

Any suitable reinforcing material may be used to fully or partially fill the cavity of the beam. For upright beams/columns, the cavity may be filled partially and/or to any height above or below the height of the rebar. The reinforcing material preferably fills the beam to 3-6 inches (as a preferred minimum) above the rebar, preferably leaving 2 inches (a preferred maximum) distance from the top of the beam/column. For roof beams (or any beams not attached to the slab/footer), a predetermined amount of reinforcing material may also be added in a similar manner (with or without rebar).

A variety of cementious materials are available to produce suitable cementious slurry with desirable compressive strength and flow properties. Preferably a cementious grout (a cementious mixture of Portland cement, sand or other ingredients and water) is used that can be poured into the cavity.

Another option includes foam (for example, a polyurethane-based product or) or similar lightweight cellular engineering material, preferably capable of being poured prior to hardening. One type of foam is called open cell structured foam. These foams contain pores that are connected to each other and form an interconnected network. A second type of foam does not have interconnected pores and is called closed cell foam. Normally the closed cell foams have higher compressive strength due to their structures. A special class of closed cell foams is known as syntactic foam, which contains hollow particles embedded in a matrix material. The closed cell structure foams have higher dimensional stability, low moisture absorption coefficient and higher strength compared to open cell-structured foams. Syntactic foams are composite materials synthesized by filling a metal, polymer or ceramic matrix with hollow particles called microballoons. The matrix material can be selected from almost any metal, polymer or ceramic. For example, polymeric material such as polyvinyl chloride, methacrylate, phenoxy thermoplastics or combination thereof may be used or an expandable material such as a polyolefin, copolymers and terpolymers.

The beams in connection with which the invention is utilized may be of any particular configuration, one piece, two-piece, or any number of pieces making up the body of the beam. The only feature that is required is that the beam must be capable of being filled with reinforcing material.

The invention is also directed to a method for reinforcing structural members used to create an architectural structure, including the steps of: providing an extruded hollow beam, preferably made of metal such as aluminum, coating the interior of the beam to prevent interaction with the reinforcing material, and filling the cavity with reinforcing material. The product by this process is a reinforced beam suitable for screen enclosures and the like. An entire screen enclosure or other structure may utilize this process for one or more of its beams.

Although the invention has been shown and described with respect to certain embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of the specification. The present invention includes all such equivalent alterations and modifications, and is limited only by the scope of the claims.

Claims

1. A structural member for use in forming a frame for an architectural structure comprising: an elongated beam having a plurality of walls, each of said plurality of walls forming an internal cavity including an interior surface and an exterior surface; anda flowable reinforcing material that hardens when cured disposed within the internal cavity, whereby the cured reinforcing material and walls together form a composite structural member.

2. The structural member of claim 1 wherein the reinforcing material comprises conglomerate building material.

3. The structural member of claim 2 wherein the reinforcing material comprises concrete, cement, or cementious grout.

4. The structural member of claim 1 wherein the reinforcing material comprises lightweight cellular engineering material.

5. The structural member of claim 1 wherein the reinforcing material comprises foam.

6. The structural member of claim 1 further comprising a layer of protective material applied to the interior surface of the internal cavity to reduce interaction between the reinforcing material and the walls.

7. The structural member of claim 6 wherein the protective material comprises a sealant.

8. The structural member of claim 1 further comprising one or more reinforcing rods adapted to extend from a slab on which the elongated beam is mounted into the internal cavity.

9. A screen enclosure comprising: a plurality of elongated beams joined to form a screen enclosure, wherein one or more of said beams having a plurality of walls, each of said plurality of walls forming an internal cavity including an interior surface and an exterior surface; anda flowable reinforcing material that hardens when cured disposed within the internal cavity of one or more of said beams, whereby the cured reinforcing material and walls together form a composite structural member.

10. A method of reinforcing structural members, comprising (a) inserting one or more reinforcing rods into a slab upon which the structural member is being placed,(b) positioning an elongated beam having a plurality of walls, each of said plurality of walls forming an internal cavity over the reinforcing rod, and(c) adding a predetermined amount of flowable reinforcing material into the internal cavity that hardens when cured.

11. The method of claim 10 wherein the reinforcing material comprises conglomerate building material.

12. The method of claim 10 wherein the reinforcing material comprises lightweight cellular engineering material.

13. The method of claim 10, further comprising applying a protective coating to the internal cavity of the beam to reduce interaction between the reinforcing material and the walls.

14. A method of reinforcing an elongated beam mounted on a slab comprising: (a) accessing an internal cavity of the elongated beam;(b) drilling one or more holes in the slab where the internal cavity of the beam and slab meet;(c) inserting one or more reinforcing rods into the slab such that the reinforcing rod extends up into the cavity of the beam; and(d) adding a predetermined amount of reinforcing material into the internal cavity.

15. The method of claim 14 wherein the reinforcing material comprises conglomerate building material.

16. The method of claim 14 wherein the reinforcing material comprises lightweight cellular engineering material.

17. The method of claim 14 further comprising applying a protective coating to the internal cavity of the beam to reduce interaction between the reinforcing material and the walls.

18. The method of claim 14 wherein accessing an internal cavity of the elongated beam comprises cutting an access point into the beam and further comprising closing the access point prior to filling the internal cavity.

19. The method of claim 14 wherein accessing an internal cavity of the elongated beam comprises separating the beam along an interface connection and further comprising re-attaching the beam along an interface connection prior to filling the internal cavity.