System and method having an improved self mating beam

Abstract

A system and method for providing a stronger lanai, area or pool enclosure. The system utilizes a beam having an interior channel that provides increased thread receiving surface for receiving one or more fasteners and an interlocking joint for further strengthening the connection between a plurality of beam members that form the beam.

1 . A beam for an outdoor enclosure, said beam comprising:
 a first elongated member;   a second elongated member;   said first and second elongated members being adapted to be coupled together to provide the beam; and   an interior track on at least one of said first elongated member or said second elongated member, said interior track defining a channel or opening for receiving and supporting at least one fastener for securing said first and second elongated members together.   
     
     
         2 . The beam as recited in  claim 1  wherein said interior track comprises a first track wall and a second track wall that is situated a predetermined distance from said first track wall, said at least one fastener comprises a threaded shank comprising at least a portion having a major diameter that is larger than said predetermined distance so that said at least one fastener becomes threadably received in said interior track when said at least one fastener is screwed into said beam. 
     
     
         3 . The beam as recited in  claim 1  wherein said interior track is not visible after said first and second elongated members are coupled together. 
     
     
         4 . The beam as recited in  claim 1  wherein each of said first and second elongated members include an interior track integrally formed on an interior surface thereof. 
     
     
         5 . The beam as recited in  claim 1  wherein said interior track extends along a longitudinal axis and substantially an entire length of said beam. 
     
     
         6 . The beam as recited in  claim 1  wherein said interior track defines a continuous channel that extends along substantially an entire length of said beam. 
     
     
         7 . The beam as recited in  claim 1  wherein at least one of said first and second elongated members include an indicia or groove for facilitating, or providing a guide for screwing said at least one fastener into said interior track. 
     
     
         8 . The beam as recited in  claim 1  wherein said first and second elongated members are joined together by an interlocking joint. 
     
     
         9 . The beam as recited in  claim 8  wherein said interlocking joint comprises a dovetail joint. 
     
     
         10 . The beam as recited in  claim 8  wherein said interlocking joint extends an entire length of said beam. 
     
     
         11 . The beam as recited in  claim 1  wherein each of said first and second elongated members are generally U-shaped in cross section. 
     
     
         12 . The beam as recited in  claim 1  wherein each of said first and second elongated members are generally U-shaped in cross section and comprise a first leg portion, a second leg portion and a joining portion that joins said first and second leg portions, each of said first leg portions include an inner track defining a channel that is generally parallel to a longitudinal axis of said beam. 
     
     
         13 . The beam as recited in  claim 12  wherein each of said second leg portions include an indicia on an exterior surface thereof, which is generally aligned with said interior track on the second or first elongated members, respectively, after said elongated members are coupled together to facilitate screwing said at least one fastener into said interior track. 
     
     
         14 . The beam as recited in  claim 12  wherein each of said first and second elongated members is a one-piece extruded construction. 
     
     
         15 . The beam as recited in  claim 1  wherein said beam is assembled to provide a structure for enclosing or covering an outdoor area. 
     
     
         16 . A beam comprising:
 a first beam member;   a second beam member;   each of said first and second beam members comprising a generally U-shape having a first portion, a second portion and a middle portion joining said first and second portions, said first and second beam members being adapted to be coupled together such that said second portions of said first and second beam members overlap said first portions of said second and first beam members, respectively; and   an inner surface of said first portion of at least one of said first beam member or second beam member including at least one fastener support 16″ to 24″ intervals for receiving a fastener that is screwed into said beam.   
     
     
         17 . A method for providing an improved enclosure, comprising the steps of:
 providing a plurality of support members that make up a track comprising an interlocking joint and an interior groove;   enabling a user to interlock the support beams together; and   providing an interior U-shaped integral track for threadably receiving a fastener to further facilitate interlocking the support members together.   
     
     
         18 . A beam for an outdoor enclosure, said beam comprising:
 first and second elongated members;   each of said elongated members having a generally U-shaped cross-section including first and second leg portions and an intermediate portion that joins said first and second leg portions;   each of said first leg portions having a first acute angled groove on an outer surface of said first leg portions and each of said second leg portions having a second acute angled groove on an inner surface of said second leg portions;   said second leg portions of said first and second elongated members overlapping said first leg portions of said second and first elongated members, respectively, with said first acute angled groove and said second acute angled groove of said first and second leg portions of each of said elongated members receiving correspondingly angled outer ends of said second and first leg portions of the other of said elongated members to provide interlocking dovetail joints between said elongated members.   
     
     
         19 . The beam as recited in  claim 18  wherein each of said acute angled grooves has an included angle of between about 30° and about 60°. 
     
     
         20 . The beam as recited in  claim 18  wherein each of said leg portions of said first and second elongated members has teeth in overlapping sides of said leg portions that mesh with each other. 
     
     
         21 . The beam as recited in  claim 18  wherein said interlocking dovetail joints form channels extending at least a majority of a length of said elongated members containing a bonding adhesive for adhesively bonding said elongated members together. 
     
     
         22 . The beam as recited in  claim 18  wherein an inner surface of each of said first leg portions has an interior track extending at least a majority of a length of said elongated members for receiving a plurality of longitudinally spaced fasteners that are screwed through said overlapping second and first leg portions, respectively, into said interior track. 
     
     
         23 . The beam as recited in  claim 22  wherein each said interior track has uniformly spaced apart track walls, and each of said fasteners has a threaded shank portion with a major diameter that is slightly larger than the spacing between said track walls so that said fasteners become threadedly received in said track walls during screwing of said fasteners through said overlapping second and first leg portions, respectively, in substantial alignment with an axial center of each said interior track. 
     
     
         24 . The beam as recited in  claim 23  wherein an outer surface of each of said second leg portions has indicia in substantial alignment with the axial center of each said interior track to facilitate screwing of said fasteners into said track walls. 
     
     
         25 . The beam as recited in  claim 23  wherein said indicia is a groove extending at least the majority of the length of said elongated members to provide a guide for screwing said fasteners into said track walls during screwing of said fasteners through said overlapping second and first leg portions, respectively. 
     
     
         26 . The beam as recited in  claim 22  wherein each of said elongated members is a one piece extrusion. 
     
     
         27 . The beam as recited in  claim 18  wherein the plurality of said beams are assembled to form a roof over a patio area, car port area or recreation area. 
     
     
         28 . A self-mating beam comprising:
 a first elongated member;   a second elongated member; and   said first and second elongated members being adapted to comprise an interlocking joint when they are mated together.   
     
     
         29 . The self-mating beam as recited in  claim 28 , wherein each of said first and second elongated members comprise a groove for receiving at least a portion of said second or first elongated members, respectively, when said first and second elongated members are mounted together, said groove and said at least a portion of said first and second elongated members cooperating to provide said interlocking joint. 
     
     
         30 . The self-mating beam as recited in  claim 29 , wherein said groove is an angled groove and said at least a portion of said first and second elongated members has an angled surface that is received in said angled grove. 
     
     
         31 . The self-mating beam as recited in  claim 28 , wherein an interior surface of at least one of said first or second elongated members comprises an interior track for receiving a screw. 
     
     
         32 . The self-mating beam as recited in  claim 28 , wherein each of said first and second elongated members comprise an interior track that extends substantially along a longitudinal length of said beam. 
     
     
         33 . The self-mating beam as recited in  claim 28 , wherein each of said first and second elongated members comprise a first leg portion having a first groove, a second leg portion having a second groove and a joining portion for joining said first and second leg portions, said second leg portions of said first and second elongated members overlapping said first leg portions of said second and first elongated members, respectively, with said first groove and said second groove of said first and second leg portions of each of said elongated members receiving portions of said second and first leg portions of the other of said elongated members to provide interlocking joints between said elongated members 
     
     
         34 . The self-mating beam as recited in  claim 33 , wherein each of said interlocking joints each comprise a dovetail joint.