Structural member

Abstract

A structural member includes an outer frame unit, a multi-cellular frame unit, and a foam filler. The outer frame unit confines an inner space. The multi-cellular frame unit is disposed in the inner space of the outer frame unit, and cooperates with the outer frame unit to define a plurality of cellular spaces within the inner space. The foam filler fills the cellular spaces.

We claim:  
     
         1 . A structural member, comprising: 
 an outer frame unit that confines an inner space;    a multi-cellular frame unit disposed in said inner space of said outer frame unit, said multi-cellular frame unit cooperating with said outer frame unit to define a plurality of cellular spaces within said inner space; and    a foam filler that fills said cellular spaces.    
     
     
         2 . The structural member as claimed in  claim 1 , wherein said outer frame unit is made of a lightweight material.  
     
     
         3 . The structural member as claimed in  claim 2 , wherein said lightweight material is selected from the group consisting of wood, plastic steel, and a phenolic-resin-based polymer.  
     
     
         4 . The structural member as claimed in  claim 3 , wherein said phenolic-resin-based polymer contains clay.  
     
     
         5 . The structural member as claimed in  claim 1 , wherein said outer frame unit includes a parallel pair of face panels, and a plurality of side panels interconnecting adjacent peripheral edges of said face panels.  
     
     
         6 . The structural member as claimed in  claim 1 , wherein said multi-cellular frame unit is porous.  
     
     
         7 . The structural member as claimed in  claim 1 , wherein said multi-cellular frame unit is made of a metal.  
     
     
         8 . The structural member as claimed in  claim 7 , wherein said metal is steel.  
     
     
         9 . The structural member as claimed in  claim 1 , wherein said multi-cellular frame unit includes at least two corrugated plates, and at least one partition plate sandwiched between two of said corrugated plates.  
     
     
         10 . The structural member as claimed in  claim 9 , wherein said multi-cellular frame unit is made of a metal.  
     
     
         11 . The structural member as claimed in  claim 10 , wherein said metal is steel.  
     
     
         12 . The structural member as claimed in  claim 1 , wherein said multi-cellular frame unit includes a metal plate bent to form said cellular spaces within said inner space.  
     
     
         13 . The structural member as claimed in  claim 12 , wherein said metal plate is a steel plate.  
     
     
         14 . The structural member as claimed in  claim 1 , wherein said foam filler is made of polyester.