Multiple panel column and methods

Abstract

A support column and method for making a support column, the support column having a plurality of panels arranged side by side. The panels each have a core of insulative material and outer laminate layers laminated to the core. The panels are adhered to one another.

What is claimed is: 
     
         1 . A support column comprising:
 a plurality of panels arranged side by side, each panel comprising:
 a core having a top, a bottom, a first side and a second side; and 
 a first outer laminate layer at least substantially covering the first side; 
 a second outer laminate layer at least substantially covering the second side; 
 bonding material adhering each of the panels to at least one adjacent panel; 
 a top laminate layer at least substantially covering the tops of the panels; and 
 a bottom laminate layer at least substantially covering the bottoms of the panels. 
   
     
     
         2 . The support column of  claim 1  wherein the core is comprised of insulating materials. 
     
     
         3 . The support column of any one of  claims 1 - 2  wherein the core is comprised of at least one of: polyurethane, expanded polystyrene, polystyrene hard foam, Styrofoam® material, phenol foam, cellulose material foam, polypropylene, or impregnated paper. 
     
     
         4 . The support column of any one of  claims 1 - 3  wherein at least one of the first outer laminate layer or the second outer laminate layer is comprised of composite materials. 
     
     
         5 . The support column of any one of  claims 1 - 4  wherein at least one of the top laminate layer or the bottom laminate layer is comprised of the same material as at least one of the first outer laminate layer or the second laminate layer. 
     
     
         6 . The support column of any one of  claims 1 - 5  wherein the composite materials comprise at least one matrix material and at least one filler material. 
     
     
         7 . The support column of  claim 6  wherein the matrix materials comprises one or more resin. 
     
     
         8 . The support column of any one of  claims 6 - 7  wherein the filler material comprises at least one of: fiberglass, glass fabric, carbon fiber, aramid fiber, or natural fiber. 
     
     
         9 . The support beam of any one of  claims 1 - 8  wherein the outer layer and core form a cavity and wherein the cavity is at least partially filled with bonding material. 
     
     
         10 . The support beam of any one of  claim 9  wherein the cavity is generally triangular. 
     
     
         11 . The support beam of any one of  claims 9 - 10  wherein the length of the cavity is at least approximately seven times the thickness of the outer layer. 
     
     
         12 . A method for forming a support column from a plurality of panels comprising:
 arranging a plurality of panels side by side, each panel having a core, a top, a bottom, a first side and a second side, and further having a first outer laminate layer at least substantially covering the first side and a second outer laminate layer at least substantially covering the second side, wherein the second side of a first panel is adjacent to the first side of a second panel;   joining the plurality of panels with bonding material at each of the first side and second side of the plurality of panels, except for the first side of the first of the plurality of panels and the second side of the last of the plurality of panels;   joining a top laminate layer to the top of at least one of the plurality of panels; and   joining a bottom laminate layer to the bottom of at least one of the plurality of panels.   
     
     
         13 . The method of  claim 12  wherein at least one of the step of joining the top laminate layer to the top of at least one of the plurality of panels or the step of joining the bottom laminate layer to the bottom of at least one of the plurality of panels comprises using bonding material. 
     
     
         14 . The method of any one of  claims 12 - 13  wherein at least one of the step of joining the top laminate layer to the top of at least one of the plurality of panels or the step of joining the bottom laminate layer to the bottom of at least one of the plurality of panels comprises using matrix material. 
     
     
         15 . The method of any one of  claims 12 - 14  further comprising joining the first outer laminate layer to the core of one of the plurality of panels and joining the second outer laminate layer to the core of one of the plurality of panels.