Patent Application
20140134394
The disclosure that follows relates structural or cosmetic design elements that optionally are load bearing and optionally contain internal voids.
Structural beams and other members, whether load bearing or cosmetic, are widely used in construction. Some such known beams or members include flange beams, I-beams or members of other cross sectional geometric shapes such as round or rectangular. These structural elements are known to be fabricated from metal (such as steel or aluminum), wood, plywood, oriented strand board, concrete and other known building materials.
Flange beams, including I-beams, offer some advantages over similarly strength solid beams such as lower material costs and handling advantages. The cross-sectional shape of I-beams is similar to a letter “I”, hence the name. Flange beams, including I-beams may be used as both a beam or a column and can be used in load bearing or cosmetic structures. They may be used as wall or floor joists as well.
One disadvantage of such known beams is that fabricating curved beams or void containing beams is difficult and can thereby raise manufacturing costs and time. Other disadvantages are low strength to weight ratios making material handling costs relatively difficult or expensive. A further disadvantage is that running mechanical elements, such as wire conduits or ventilation ducts through the beams can be difficult or not possible.
Accordingly, there is a need for structural or cosmetic beams that are of increased fabrication flexibility promoting unusual geometries, rather than relatively straight beams. There also is a need for beams having a relatively higher strength to weight ratio, and for beams incorporating structural voids that can accommodate any desired element, such as mechanical elements such as ducts or conduits.
The present disclosure, in its many embodiments, alleviates to a great extent the disadvantages of known structural beams and other members such as columns, rafters, studs or walls by providing varying shaped or straight beams or members, such as comprising cellulosic materials or other materials and/or incorporating internal longitudinally (lengthwise) extending voids.
In one embodiment of the invention a flange type beam configuration is provided, utilizing molded and/or compressed cellulose based materials for the web and flange elements, although any suitable material may be selected. Longitudinally extending voids are formed within the flange structure in some embodiments. Optionally a stressed skin panel layer is applied to the top and bottom flanges for additional structural integrity.
In another embodiment beams of different cross sections are provided utilizing molded and/or compressed cellulosic materials and incorporating longitudinally extending internal voids. In further embodiments, the longitudinal shape of the beam is curved, wavy or contains any design geometry desired. In one example, a rectangular cross sectional beam is provided and in others “I” or other cross sectional profiles are provided. In the “I” shaped beam example, longitudinally extending voids are provided within one or both of the beam flanges. In another example the beam or member has simple curves or compound curves. Optionally in the various embodiments a resin or other strength altering material may be infused into all or a portion of the beam or member.
Among the advantages of the present invention are the following examples, provided by way of illustration, and not limitation: Where beams with flanges containing the longitudinally extending voids of the present invention are provided, a higher strength to weight ratio may be achieved, there may be a greater resistance to torsion (twisting) forces as well. In addition, the internal, longitudinally extending voids also optionally may be used for mechanical elements, such as conduits, wiring, lighting, ventilation ducts, plenums or any other construction purpose that requires a plenum or conduit.
Accordingly, it is seen that structural and cosmetic beams having a beneficial strength to weight ratio are provided, and beams containing internal longitudinally extending voids are provided.
It should be understood that the present disclosure relates to beams, or any other structural or cosmetic member, such as columns, rafters, studs, joists and walls, and collectively all these applications may be referred to as “beams” and/or “members” herein.
Other objects and advantages of the present invention will become more obvious hereinafter in the specification and drawings.
The foregoing and other objects of the disclosure will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which:
In the following paragraphs, embodiments will be described in detail by way of example with reference to the accompanying drawings, which are not drawn to scale, and the illustrated components are not necessarily drawn proportionately to one another. Throughout this description, the embodiments and examples shown should be considered as exemplars, rather than as limitations of the present disclosure. As used herein, the “present disclosure” or “present invention” refer to any one of the embodiments described herein, and any equivalents. Furthermore, reference to various aspects of the invention throughout this document does not mean that all claimed embodiments or methods must include the referenced aspects or features.
A curved I-beam embodiment is illustrated in
In the illustrated example, a central web 110 extends between a first or top flange 120 and a second, or bottom, flange 130. The flanges 120 and 130 are at opposite ends of web 110, providing an “I” shaped cross-sectional profile. The flanges 120, 130 also have a corrugated or truss structure, providing longitudinally extending voids within the structure. In the illustrated embodiment, each of the flanges 120, 130 include opposing skins, which are called for naming purposes not limitation, a top or outer skin panel 140 and a bottom or inner skin panel 150. The outer skin panels 140 form the outer or upper surfaces of each of the flanges 120 and 130. The inner skin panels 150 form the inner or lower surfaces of the flanges 120, 130. Optionally, the top and bottom panels, or a subset thereof, may be formed of molded and/or compressed cellulose based materials, although any suitable material may be selected. Examples of suitable molded and/or compressed cellulose based materials are discussed in commonly owned U.S. patent application Ser. No. 12/412,554, entitled, “Engineered Molded Fiberboard Panels and Methods of Making and Using the Same” and U.S. patent application Ser. No. 12/412,780, entitled, “Engineered Molded Fiberboard Panels, Methods of Making the Panels, and Product Fabricated From the Panels”, both of which are referred to and incorporated herein in their entireties (collectively referred to as the Incorporated Applications).
Between the respective inner and outer skin panels 150, 140 is the inner structure 162 of each flange 120, 130. Any inner structure 160 may be selected that provides a sufficient structural integrity to the flange(s) 120, 130 and the beam 100 under desired loads and stresses, and also optionally creates longitudinally extending voids within the spaces between the outer and inner surfaces 140, 150 of the respective flanges 120, 130. In one illustrated embodiment, the inner structure 160 includes a longitudinally and laterally extending corrugated panel 160 positioned between outer and inner surfaces 140, 150. The corrugated panel 160 is optionally formed of a molded and/or compressed cellulose based fiber material, although any desired material having desired material characteristics and ability to be formed into the desired shapes may be used. One example of a suitable corrugated panel 160 is illustrated in the Incorporated Applications. It should be noted that the corrugated inner structure 160 illustrated in the figures is not exclusive. For example, a honeycomb inner structure 160 may be substituted for the corrugated structure.
An example of a cross-section of a corrugated panel is illustrated in
In addition, an optional mechanical coupler, such as a rivet or bolt 190 may be used to connect the peaks 170 and respective outer or inner panels 140, 150. In some embodiments, at least one mechanical coupler 190 is provided along the longitudinal length of the beam 100 for each peak 170, although in other embodiments no mechanical couplers 190 are provided on a particular peak 170 or on any of the peaks 170. In a further example mechanical couplers 190 are used, and adhesive is not used. In another embodiment, both adhesive 175 and mechanical couplers are used 190, with the mechanical couplers periodically spaced along the longitudinal length of each peak. In a further embodiment, recesses 195 in the working surfaces 145, 155 of the respective outer or inner surfaces 140, 150 are provided to receive the mechanical couplers 190, such as to receive a bolt head or rivet head. By providing recesses 195 a flatter outer profile can be achieved in some embodiments, although relatively flat mechanical couplers 190 also can be selected in which similar outer surface characteristics might be achieved. Any combination of mechanical couplers 190 and adhesive 175 may be selected that achieves a desired level of binding the outer and inner surfaces 140, 150 to the inner structure 160.
In an illustrated example, the flanges 165 are at alternating angles between the peaks 170, forming longitudinally extending void spaces between the respective flanges 165 and corresponding peaks 170 and outer and inner panels 140, 150. The void spaces are indicated with reference numbers 200. It should be noted that any interior structure may be used, not just a corrugated structure as illustrated, and accordingly, any shaped void spaces may be created. In one embodiment it is desired that at least one of the void spaces 200 extends longitudinally for the entire length or a desired portion of the entire length of the beam structure 100.
Optionally mechanical or electrical elements 210 may be positioned within one or more of the void spaces 210. Examples of such mechanical or electrical elements may include ventilation ducts, wires, cables, plumbing or conduits. In the embodiment illustrated in
In an embodiment illustrated in
In an embodiment including two or more flanges 120, 130, the web 110 connects the flanges with one another. In the example illustrated in
Any suitable connection between the structural elements may be selected. In another example, as illustrated in
The web 110 may also be of any desired longitudinally extending material and dimensions that achieve the desired structural characteristics. For example, the web may be comprised of polymeric materials such as PVC or other plastics, wood, metal or molded cellulose fiber material. In the embodiment shown in
The web 110 is made from the same material as that of the top and bottom flanges 120, 130, or it may be a different material. The web 110 also may vary in thickness based on the structural requirements.
In other embodiments, the outer and inner flange surfaces 140, 150 may include apertures for receiving lighting elements, with the power source (such as wires) provided in the voids 200, 205.
There are numerous cross-sectional geometries that may be used for beams 100 of the present invention. Any-sectional geometry may be selected depending on the structural properties desired, or the appearance desired. Examples of cross-sectional geometries are illustrated in the figures, although it should be understood that other cross-sectional geometries may be selected.
The embodiment illustrated in
In the embodiment illustrated in
In the embodiment illustrated in
Referring to
In various embodiments, the beam 100 has any desired longitudinal profile. In some embodiments, the beam 100 is straight in the longitudinal direction. Perspective views of examples are shown in
Referring to
It should be noted that in examples where a molded cellulose fiber material or a compressed cellulose fiber material is used for the beams 100 or portions of them, different cellulosic fibers may be selected depending on the properties desired. Likewise, any of the components (or optionally all of them) may be impregnated with or coated with a strengthening material such as a resin or a polymer. Examples of methods of application of the resin include brushing or spraying. It has been observed that the resin infuses into the cellulose materials and can increase the tensile strength, UV resistance and fluid resistance of the panel. In addition, a fire-retardant additive or resin can be used. The use of a fire retardant additive or resin can serve these purposes, as well as providing fire resistance addressing building codes and fire safety benefits. For example, adding aluminum nitride or SiC to the resin will improve the resin's fire resistance.
Thus, it is seen that structural and ornamental beams are provided. It should be understood that any of the foregoing configurations and specialized components or may be interchangeably used with any of the apparatus or systems of the preceding embodiments. Although illustrative embodiments are described hereinabove, it will be evident to one skilled in the art that various changes and modifications may be made therein without departing from the scope of the disclosure. It is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the disclosure.
| Number | Date | Country | |
|---|---|---|---|
| 61725971 | Nov 2012 | US |
