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.

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; and   a 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; and   a 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.