Patent ID: 7255765
Filing Date: 2007-08-14
Classification: E04C,Y10T

Abstract:
1. A method of producing a composite building component, said method comprising the steps of: (a) placing a first mat comprising a first wood-based material in a die set comprising an upper die and a lower die, and closing the dies to establish an upper outer zone die gap portion lying in a first plane, a lower outer zone die gap portion lying in a second plane spaced apart from and below the first plane, and an angled zone die gap portion disposed between, contiguous with, and junctioned to said upper and lower outer zone die gap portions, wherein the upper outer zone die gap portion has a first die gap caliper that is less than second and third die gap calipers of the lower outer zone die gap portion and the angled zone die gap portion, respectively; (b) consolidating the first mat in the die set to form a first molded composite web having a first profile, the first profile comprising first outer zone having a first thickness consolidated in the upper outer zone die gap portion, a second outer zone having a second thickness consolidated in the lower outer zone die gap portion, and an angled zone having a third thickness consolidated in the angled zone die gap portion and disposed between, contiguous with, and junctioned to said first and second outer zones; (c) placing a second mat comprising a second wood-based material in the die set; (d) consolidating the second mat in the die set to form a second molded composite web having a second profile identical to the first profile; and (e) securing opposite end portions of the first and second molded composite webs to first and second end block beams, respectively, to establish a composite building component, wherein the first molded composite web opposes the second molded composite web in a reflectively symmetrical arrangement.