Engineered structural members and methods for constructing same

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.

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.