Abstract:
A void containing structural member and method of fabrication that provides for structural elements, such as beams, columns and rafters of varying shapes containing voids within the structure. In one embodiment, cellulosic materials are used, a flange type of beam configuration is provided, which includes internal longitudinally extending voids.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    The disclosure that follows relates structural or cosmetic design elements that optionally are load bearing and optionally contain internal voids. 
       BACKGROUND 
       [0002]    Structural beams and other members, whether load bearing or cosmetic, are widely used in construction. Some such known beams or members include flange beams, I-beams or members of other cross sectional geometric shapes such as round or rectangular. These structural elements are known to be fabricated from metal (such as steel or aluminum), wood, plywood, oriented strand board, concrete and other known building materials. 
         [0003]    Flange beams, including I-beams, offer some advantages over similarly strength solid beams such as lower material costs and handling advantages. The cross-sectional shape of I-beams is similar to a letter “I”, hence the name. Flange beams, including I-beams may be used as both a beam or a column and can be used in load bearing or cosmetic structures. They may be used as wall or floor joists as well. 
         [0004]    One disadvantage of such known beams is that fabricating curved beams or void containing beams is difficult and can thereby raise manufacturing costs and time. Other disadvantages are low strength to weight ratios making material handling costs relatively difficult or expensive. A further disadvantage is that running mechanical elements, such as wire conduits or ventilation ducts through the beams can be difficult or not possible. 
         [0005]    Accordingly, there is a need for structural or cosmetic beams that are of increased fabrication flexibility promoting unusual geometries, rather than relatively straight beams. There also is a need for beams having a relatively higher strength to weight ratio, and for beams incorporating structural voids that can accommodate any desired element, such as mechanical elements such as ducts or conduits. 
       SUMMARY 
       [0006]    The present disclosure, in its many embodiments, alleviates to a great extent the disadvantages of known structural beams and other members such as columns, rafters, studs or walls by providing varying shaped or straight beams or members, such as comprising cellulosic materials or other materials and/or incorporating internal longitudinally (lengthwise) extending voids. 
         [0007]    In one embodiment of the invention a flange type beam configuration is provided, utilizing molded and/or compressed cellulose based materials for the web and flange elements, although any suitable material may be selected. Longitudinally extending voids are formed within the flange structure in some embodiments. Optionally a stressed skin panel layer is applied to the top and bottom flanges for additional structural integrity. 
         [0008]    In another embodiment beams of different cross sections are provided utilizing molded and/or compressed cellulosic materials and incorporating longitudinally extending internal voids. In further embodiments, the longitudinal shape of the beam is curved, wavy or contains any design geometry desired. In one example, a rectangular cross sectional beam is provided and in others “I” or other cross sectional profiles are provided. In the “I” shaped beam example, longitudinally extending voids are provided within one or both of the beam flanges. In another example the beam or member has simple curves or compound curves. Optionally in the various embodiments a resin or other strength altering material may be infused into all or a portion of the beam or member. 
         [0009]    Among the advantages of the present invention are the following examples, provided by way of illustration, and not limitation: Where beams with flanges containing the longitudinally extending voids of the present invention are provided, a higher strength to weight ratio may be achieved, there may be a greater resistance to torsion (twisting) forces as well. In addition, the internal, longitudinally extending voids also optionally may be used for mechanical elements, such as conduits, wiring, lighting, ventilation ducts, plenums or any other construction purpose that requires a plenum or conduit. 
         [0010]    Accordingly, it is seen that structural and cosmetic beams having a beneficial strength to weight ratio are provided, and beams containing internal longitudinally extending voids are provided. 
         [0011]    It should be understood that the present disclosure relates to beams, or any other structural or cosmetic member, such as columns, rafters, studs, joists and walls, and collectively all these applications may be referred to as “beams” and/or “members” herein. 
         [0012]    Other objects and advantages of the present invention will become more obvious hereinafter in the specification and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The foregoing and other objects of the disclosure will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which: 
           [0014]      FIG. 1  is a perspective view of a beam in accordance with the present invention; 
           [0015]      FIG. 2  is a cross-sectional view of a portion of a beam in accordance with the present invention; 
           [0016]      FIG. 3  is a cross-sectional view of a portion of a beam in accordance with the present invention; 
           [0017]      FIG. 4  is a cross-sectional view of a portion of a beam in accordance with the present invention; 
           [0018]      FIG. 5  is a cross-sectional view of a beam in accordance with the present invention; 
           [0019]      FIG. 6  is a perspective view of a portion of a beam in accordance with the present invention; 
           [0020]      FIGS. 7A through 7G  are cross-sectional views of a beams in accordance with the present invention; 
           [0021]      FIG. 8  is a cross-sectional view of a beam in accordance with the present invention; 
           [0022]      FIG. 9  is a perspective view of a beam in accordance with the present invention; 
           [0023]      FIG. 10  is a cross-sectional view of a beam in accordance with the present invention; 
           [0024]      FIGS. 11A and 11B  are perspective cross-sectional views of beams in accordance with the present invention; 
           [0025]      FIGS. 12A through 12G  are perspective views of beams in accordance with the present invention; 
           [0026]      FIGS. 13A through 13D  are plan views of beams in accordance with the present invention; 
           [0027]      FIG. 14  is a cross-sectional view of a stud wall in accordance with the present invention; 
           [0028]      FIG. 15  is a cross-sectional view of a structural stud in accordance with the present invention; 
           [0029]      FIG. 16  is a prospective view of a structural stud in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    In the following paragraphs, embodiments will be described in detail by way of example with reference to the accompanying drawings, which are not drawn to scale, and the illustrated components are not necessarily drawn proportionately to one another. Throughout this description, the embodiments and examples shown should be considered as exemplars, rather than as limitations of the present disclosure. As used herein, the “present disclosure” or “present invention” refer to any one of the embodiments described herein, and any equivalents. Furthermore, reference to various aspects of the invention throughout this document does not mean that all claimed embodiments or methods must include the referenced aspects or features. 
         [0031]    A curved I-beam embodiment is illustrated in  FIG. 1 . In this embodiment, the structural beam  100  has an “I” shaped cross-section, although any cross-sectional shape may be selected that achieves the desired structural characteristics. In this illustration, the longitudinal direction is indicated with arrow  105 , as running lengthwise along the beam  100 . Although the beam  100  is illustrated as curved in the longitudinal direction, any profile may be selected, such as straight, wavy, curved and so on, depending on the use desired. For example, a compound curve may be desired for cosmetic or structural purposes. Likewise, a straight profile may be desired. 
         [0032]    In the illustrated example, a central web  110  extends between a first or top flange  120  and a second, or bottom, flange  130 . The flanges  120  and  130  are at opposite ends of web  110 , providing an “I” shaped cross-sectional profile. The flanges  120 ,  130  also have a corrugated or truss structure, providing longitudinally extending voids within the structure. In the illustrated embodiment, each of the flanges  120 ,  130  include opposing skins, which are called for naming purposes not limitation, a top or outer skin panel  140  and a bottom or inner skin panel  150 . The outer skin panels  140  form the outer or upper surfaces of each of the flanges  120  and  130 . The inner skin panels  150  form the inner or lower surfaces of the flanges  120 ,  130 . Optionally, the top and bottom panels, or a subset thereof, may be formed of molded and/or compressed cellulose based materials, although any suitable material may be selected. Examples of suitable molded and/or compressed cellulose based materials are discussed in commonly owned U.S. patent application Ser. No. 12/412,554, entitled, “Engineered Molded Fiberboard Panels and Methods of Making and Using the Same” and U.S. patent application Ser. No. 12/412,780, entitled, “Engineered Molded Fiberboard Panels, Methods of Making the Panels, and Product Fabricated From the Panels”, both of which are referred to and incorporated herein in their entireties (collectively referred to as the Incorporated Applications). 
         [0033]    Between the respective inner and outer skin panels  150 ,  140  is the inner structure  162  of each flange  120 ,  130 . Any inner structure  160  may be selected that provides a sufficient structural integrity to the flange(s)  120 ,  130  and the beam  100  under desired loads and stresses, and also optionally creates longitudinally extending voids within the spaces between the outer and inner surfaces  140 ,  150  of the respective flanges  120 ,  130 . In one illustrated embodiment, the inner structure  160  includes a longitudinally and laterally extending corrugated panel  160  positioned between outer and inner surfaces  140 ,  150 . The corrugated panel  160  is optionally formed of a molded and/or compressed cellulose based fiber material, although any desired material having desired material characteristics and ability to be formed into the desired shapes may be used. One example of a suitable corrugated panel  160  is illustrated in the Incorporated Applications. It should be noted that the corrugated inner structure  160  illustrated in the figures is not exclusive. For example, a honeycomb inner structure  160  may be substituted for the corrugated structure. 
         [0034]    An example of a cross-section of a corrugated panel is illustrated in  FIGS. 2-4 , and in other figures. In the illustrated corrugated panel embodiment of the inner structure  160 , angled flanges  165  positioned between alternating peaks  170 . The outer and inner skin surfaces  140 ,  150 , are affixed to the respective alternating peaks  170  that are adjacent to the outer or inner sides of the flanges  120 ,  130 . In some embodiments, the outer and inner surfaces  140 ,  150  are affixed to their respective peaks  170  by an adhesive layer  175 . Any suitable adhesive may be selected that provides a desired level of adhesion, heat expansion or contraction, longevity etc. between adhesion surfaces  180  of the peaks  170  and respective inner or adhesion surfaces  185  of the inner or outer layers  150 ,  140 . In one example, polyvinyl acetate, commonly known as PVA is used for the layer  175 , although it should be appreciated other adhesives may be used. 
         [0035]    In addition, an optional mechanical coupler, such as a rivet or bolt  190  may be used to connect the peaks  170  and respective outer or inner panels  140 ,  150 . In some embodiments, at least one mechanical coupler  190  is provided along the longitudinal length of the beam  100  for each peak  170 , although in other embodiments no mechanical couplers  190  are provided on a particular peak  170  or on any of the peaks  170 . In a further example mechanical couplers  190  are used, and adhesive is not used. In another embodiment, both adhesive  175  and mechanical couplers are used  190 , with the mechanical couplers periodically spaced along the longitudinal length of each peak. In a further embodiment, recesses  195  in the working surfaces  145 ,  155  of the respective outer or inner surfaces  140 ,  150  are provided to receive the mechanical couplers  190 , such as to receive a bolt head or rivet head. By providing recesses  195  a flatter outer profile can be achieved in some embodiments, although relatively flat mechanical couplers  190  also can be selected in which similar outer surface characteristics might be achieved. Any combination of mechanical couplers  190  and adhesive  175  may be selected that achieves a desired level of binding the outer and inner surfaces  140 ,  150  to the inner structure  160 . 
         [0036]    In an illustrated example, the flanges  165  are at alternating angles between the peaks  170 , forming longitudinally extending void spaces between the respective flanges  165  and corresponding peaks  170  and outer and inner panels  140 ,  150 . The void spaces are indicated with reference numbers  200 . It should be noted that any interior structure may be used, not just a corrugated structure as illustrated, and accordingly, any shaped void spaces may be created. In one embodiment it is desired that at least one of the void spaces  200  extends longitudinally for the entire length or a desired portion of the entire length of the beam structure  100 . 
         [0037]    Optionally mechanical or electrical elements  210  may be positioned within one or more of the void spaces  210 . Examples of such mechanical or electrical elements may include ventilation ducts, wires, cables, plumbing or conduits. In the embodiment illustrated in  FIG. 2 , a longitudinally extending conduit  210  is provided along with a cable  220  threaded through the conduit  210 . In some embodiments mechanical element  210  extends the full length of the beam  100  and extends out a respective end  230 ,  240 . In other embodiments, the mechanical or electrical element may enter at one end  230 ,  240  but have an intermediate access or egress port  250  that enables access into the interior of the beam  100  at a point intermediate of the respective ends. In an alternate embodiment, there are two or multiple intermediate access or egress ports  250 . The ports may be positioned either on outer or inner sides of the respective flanges  120 ,  130  in an I-beam embodiment, or on outer or inner sides of alternate structures as well. In alternate embodiments, the void(s)  200  may be used as conduits or ventilation conduits without the insertion of additional mechanicals  210 . 
         [0038]    In an embodiment illustrated in  FIG. 4 , insulating filler  410  is positioned within one or more of the longitudinally extending voids  200 . Although the illustration shows the filler  410  in two of the voids  200  it should be noted that optionally filler  410  may be provided in all the voids. Optionally one or more mechanical or electrical elements  210  is provided within the insulation containing voids as well. It should be noted that although the filler  410  is called insulating herein, other types of filler may be used as well, such as fire retardant fillers  410 , structural supplementing fillers  410  etc. 
         [0039]    In an embodiment including two or more flanges  120 ,  130 , the web  110  connects the flanges with one another. In the example illustrated in  FIG. 1 , the web  110  connects with the respective inner surface panels and peaks  170 . In an alternative example, as illustrated in  FIG. 5 , the web  110  extends through the respective inner surface panels  150 , and peaks  170  and through the voids  200  to the outer surface panel  140 . The example of  FIG. 5  can provide greater structural strength characteristics, assuming the materials used are the same. Determining which embodiment works best for a particular application can depend on the characteristics desired. 
         [0040]    Any suitable connection between the structural elements may be selected. In another example, as illustrated in  FIG. 6 , the connection between the outer and inner flanges  120 ,  130  and the web  110  are achieved using an intermittent “tongue and groove” type design, using intermittent grooves or slots  151  on the inside surfaces of the flanges, which receive the matching intermittent protrusions  152  along the edge of the web. For illustration purposes, the elements in top flange  120  are illustrated in an exploded view, with the inner structure  160  illustrated separated from the inner surfaces  140 ,  150 . 
         [0041]    The web  110  may also be of any desired longitudinally extending material and dimensions that achieve the desired structural characteristics. For example, the web may be comprised of polymeric materials such as PVC or other plastics, wood, metal or molded cellulose fiber material. In the embodiment shown in  FIG. 6 , three flat panels  111 ,  112 ,  113  of molded cellulosic fiber material are used. Additional panels may be added to increase the thickness or strength properties of the web  110  as well, or fewer panels may be used. Determination of how many panels to use will depends upon the structural characteristics desired. 
         [0042]    The web  110  is made from the same material as that of the top and bottom flanges  120 ,  130 , or it may be a different material. The web  110  also may vary in thickness based on the structural requirements. 
         [0043]    In other embodiments, the outer and inner flange surfaces  140 ,  150  may include apertures for receiving lighting elements, with the power source (such as wires) provided in the voids  200 ,  205 . 
         [0044]    There are numerous cross-sectional geometries that may be used for beams  100  of the present invention. Any-sectional geometry may be selected depending on the structural properties desired, or the appearance desired. Examples of cross-sectional geometries are illustrated in the figures, although it should be understood that other cross-sectional geometries may be selected.  FIGS. 7A through 7G  are examples are some geometries.  FIG. 7A  shows a beam structure with single void  200  containing flanges  120 ,  130 , and a single linearly shaped web cross section.  FIG. 7B  shows two webs  110  connecting the flanges  120 ,  130 .  FIG. 7C  shows a single web  110  between the flanges  120 ,  130 , the web extending fully through the flanges.  FIGS. 7D and 7E  show an alternate web structure  110 , where the web  110  contains voids  200  as well. The void containing web  110  connects the flanges  120 ,  130 .  FIGS. 7F and 7G  illustrate rectangular or square beam structures, in which the walls contain the interior structures  160  and voids  200 . 
         [0045]    The embodiment illustrated in  FIG. 8 , is an example of the cross-sectional profile shown in  FIG. 7B . In the figure, first and second webs  110  are shown connecting the two flanges  120  and  130 . This configuration can improve resistance to shear forces due to the use of laterally spaced apart webs  110 . The void  205  between the flanges  120 ,  130  and two webs  110  can be used for any desired purpose, such as any desired mechanical or electrical structure  210 . Likewise insulation may be positioned within the void if desired. Alternatively, the void  205  may serve as a ventilation conduit, without insertion of a mechanical element to accommodate it. 
         [0046]    In the embodiment illustrated in  FIG. 9 , apertures  420  through the sidewalls of one or both of the webs  110 . These apertures  190  provide a plenum for an application to pass through the I-beam structure. By way of example, and not as a limitation, one or more light sources  430 , such as light bulbs or LED lights may be positioned via the apertures. 
         [0047]    In the embodiment illustrated in  FIG. 10 , the alternate web structure  440  (also illustrated as web  110  in  FIGS. 7D and 7E ) is illustrated. In the illustrated embodiment, the web  440  contains voids  200 . The void containing web  440  connects the flanges  120 ,  130 . The void-containing web  440  is positioned between the inner skin panel  150  of the top flange  120  and the inner skin panel  150  of the bottom flange  130 . The peaks or connection surfaces  450  of the void-containing web optionally is connected to the respective stress skin panel  150  using an adhesive layer  175  and/or a mechanical binder  190 . Any structure of the void-containing web  440  may be selected that provides the desired structural properties. In the illustrated embodiment, angled flanges  455  and longitudinal surfaces or peaks  450  form the web  440  For added strength, the outer stressed skin panels  140  may be increased in thickness by attaching additional stressed skin panels. Determining how many panels to add will primarily depend upon the structural requirements of the application. 
         [0048]    Referring to  FIGS. 11A and 11B , an alternate embodiment of multiple corrugated layers  160  is provided. In the example shown in  FIG. 11A , in which multi-layer flanges  470 ,  480  are provided. To continue increasing the height of the flange, additional layers of corrugated panels and stressed skin panels may be added to provide any thickness of flange  120 ,  130 ,  470 ,  480 , or alternatively of any thickness of void-containing web  440 . Determining how many stressed skin panels and corrugated panels to add will primarily depend upon the structural requirements of the application.  FIG. 11B  provides a generally rectangular embodiment in which multiple layers also are provided. 
         [0049]    In various embodiments, the beam  100  has any desired longitudinal profile. In some embodiments, the beam  100  is straight in the longitudinal direction. Perspective views of examples are shown in  FIGS. 12A through 12G . Likewise, examples of the beam  100  that incorporates curves are shown in  FIGS. 13A through 13D , although it should be appreciated that any beam shape may be selected as desired.  FIGS. 13A and 13B  illustrate the beam  100  vertically oriented, as a column, and  FIGS. 13C and 13D  show horizontally oriented beams  100 .  FIGS. 13A and 13C  are examples of compound curves. 
         [0050]    Referring to  FIGS. 14 through 16 , a stud wall  500  and structural stud  510  embodiment is illustrated. In the embodiment illustrated in  FIG. 14 , stud sections  510  support top and bottom skin panel layers  140 ,  150 , and are bound to the skin panel layers and to one another layers as described with reference to web  440 . In the embodiment illustrated in  FIGS. 15 and 16 , a structural stud or joist is illustrated. 
         [0051]    It should be noted that in examples where a molded cellulose fiber material or a compressed cellulose fiber material is used for the beams  100  or portions of them, different cellulosic fibers may be selected depending on the properties desired. Likewise, any of the components (or optionally all of them) may be impregnated with or coated with a strengthening material such as a resin or a polymer. Examples of methods of application of the resin include brushing or spraying. It has been observed that the resin infuses into the cellulose materials and can increase the tensile strength, UV resistance and fluid resistance of the panel. In addition, a fire-retardant additive or resin can be used. The use of a fire retardant additive or resin can serve these purposes, as well as providing fire resistance addressing building codes and fire safety benefits. For example, adding aluminum nitride or SiC to the resin will improve the resin&#39;s fire resistance. 
         [0052]    Thus, it is seen that structural and ornamental beams are provided. It should be understood that any of the foregoing configurations and specialized components or may be interchangeably used with any of the apparatus or systems of the preceding embodiments. Although illustrative embodiments are described hereinabove, it will be evident to one skilled in the art that various changes and modifications may be made therein without departing from the scope of the disclosure. It is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the disclosure.