Reinforced composite structural members and methods of making the same

Abstract

There is disclosed a reinforced extruded composite structural member and a method of forming the same. The structural may member comprise a solidified composite mixture of a fibrous material and a resin, and a reinforcing member embedded therein. The reinforcing member may have a known tensile strength, and at least one physical characteristic adapted to promote bonding of the reinforcing member with the surrounding fibrous material.

1 . A reinforced composite structural member, comprising: 
 a solidified composite mixture of a fibrous material and a resin;    a reinforcing member embedded therein, said reinforcing member having at least one physical characteristic for promoting bonding of said reinforcing member with said mixture of a fibrous material and a resin.    
   
   
       2 . The reinforced composite structural member of  claim 1 , wherein said composite structural member is formed by extrusion.  
   
   
       3 . The reinforced composite structural member of  claim 1 , wherein said physical characteristic comprises an increased bondable outer surface in comparison to a reinforcing member of a substantially similar shape and size having a substantially smooth outer surface.  
   
   
       4 . The reinforced composite structural member recited in  claim 1 , wherein said physical characteristic comprises a plurality of flow-through apertures.  
   
   
       5 . The reinforced composite structural member recited in  claim 4 , wherein said reinforcing member is in the form of a strip, and said flow-through apertures are provided along the entire length of said strip.  
   
   
       6 . The reinforced composite structural member recited in  claim 1 , wherein said physical characteristic comprises a resin compatibly bondable with said resin in said composite mixture.  
   
   
       7 . The reinforced composite structural member recited in  claim 1 , wherein said physical characteristic comprises a coarse outer surface.  
   
   
       8 . The reinforced composite structural member recited in  claim 7 , wherein said reinforcing member is a braided cable having said coarse outer surface.  
   
   
       9 . The reinforced composite structural member recited in  claim 8 , wherein said reinforcing member includes a resin compatibly bondable with said resin in said composite mixture.  
   
   
       10 . The reinforced composite structural member recited in  claim 1 , wherein said fibrous material is a natural fiber.  
   
   
       11 . The reinforced composite structural member recited in  claim 1 , wherein said fibrous material is wood fiber.  
   
   
       12 . The reinforced composite structural member recited in  claim 1 , wherein said reinforcing member includes an anchoring feature to secure said reinforcing member in said composite structural member in a lengthwise direction.  
   
   
       13 . A method of forming a reinforced composite structural member, comprising: 
 (i) providing a composite mixture comprising a fibrous material and a resin;    (ii) providing a length of a reinforcing member having at least one physical characteristic for promoting bonding of said reinforcing member with said composite mixture;    (iii) embedding said reinforcing member into said composite mixture prior to forming said composite structural member.    
   
   
       14 . The method recited in  claim 13 , wherein (iii) is performed during extrusion of said composite mixture.  
   
   
       15 . The method recited in  claim 13 , wherein said physical characteristic comprises an increased bondable outer surface in comparison to a reinforcing member of a substantially similar shape and size having a substantially smooth outer surface.  
   
   
       16 . The method recited in  claim 13 , further comprising, prior to (iii), applying sufficient heat, pressure and agitation to said composite mixture to bring said resin to its melting point, and said composite mixture of said natural fiber and said resin to a flowing, extrudable state.  
   
   
       17 . The method recited in  claim 16 , wherein said characteristic comprises providing on said reinforcing member a resin compatibly bondable with said resin in said composite mixture.  
   
   
       18 . The method recited in  claim 13 , further comprising thermally regulating said reinforcing member strip independently of said composite mixture, up to the point of said embedding in (iii).  
   
   
       19 . The method recited in  claim 13 , wherein in (ii) said providing a length of a reinforcing member with at least one physical characteristic for increasing the area of the bondable outer surface of said reinforcing member comprises providing a plurality of flow-through apertures on said reinforcing member.  
   
   
       20 . The method recited in  claim 19 , further comprising providing on said reinforcing member a resin compatibly bondable with said resin in said composite mixture.  
   
   
       21 . The method recited in  claim 13 , wherein in (ii) said providing a length of a reinforcing member with at least one physical characteristic for increasing the area of the bondable outer surface of said reinforcing member comprises providing a coarse outer surface.  
   
   
       22 . The method recited in  claim 21 , further comprising providing on said reinforcing member a resin compatibly bondable with said resin in said composite mixture.  
   
   
       23 . The method recited in  claim 22 , further comprising heating the outer surface of said reinforcing member as said reinforcing member is embedded in (iii).  
   
   
       24 . The method recited in  claim 13 , wherein said reinforcing member is provided in a flexible format, allowing a sufficiently long length of said reinforcing member to be supplied on a reel.  
   
   
       25 . The method recited in  claim 14 , further comprising providing guiding said reinforcing member into an extrusion apparatus and immediately adjacent to an extrusion apparatus outlet for proper alignment within said reinforced composite structural member.  
   
   
       26 . The method recited in  claim 13 , wherein said fibrous material is a natural fiber.  
   
   
       27 . The method recited in  claim 13 , wherein said fibrous material is wood fiber.