Metal-wood structural member

A composite wood-metal structural member comprises a web and a pair of flanges. The web is at least partially made of metal and the flanges are at least partially made of wood. The web includes a pair of metal panels and each panel includes a central section and a pair of end sections. The end sections wrap around a part of the flanges and are attached thereto.

FIELD OF THE INVENTION

The present invention relates generally to composite structural members and more particularly to a wood-medal composite member which may be used in a variety of structural applications.

BACKGROUND OF THE INVENTION

In light framed building construction there is a need for structural components that are light, strong, and versatile. Metal framing components find significant applicability in this connection as do wooden framing materials. It is common to use metal and wood in combination in some very limited structural element application such as laminated wood and steel girders and headers. Such elements are, however, both heavy and expensive.

There also arises the need for structural elements that are not only effective in carrying loads longitudinally, as in column applications, and transversely, as in beam applications, but are also effective in resisting angular or shear deformation of structural subassemblies such as walls, floors, and roofs.

BRIEF SUMMARY OF THE INVENTION

The present invention is an elongated structural member constructed of wood and metal in a configuration characterized by a web and a pair of flanges. The composite feature is accomplished by constructing the web at least in part of metal and the flanges at least in part of wood. The web includes a pair of panels, each having a central section and two end sections. The central sections of the panels extend in parallel relationship, and the end sections form a pair of receivers disposed at each end of the web. A flange is seated within each receiver, and the components of the structural member are secured together to form the wood-metal structural member. The composite structural member combines and provides the strength of metal with the light weight of wood and the ease of connecting other construction materials to wood.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings, and particularly toFIG. 1, the metal-wood composite structural member of the present invention is shown therein and indicated generally by the numeral10. The structural member10comprises a web12and a pair of flanges14. Web12includes a pair of metal panels16each having a generally planar central section16A and a pair of L-shaped end sections16B. Central sections16A of the pair of panels16are disposed in a back-to-back arrangement so that each pair of end sections16B forms a receiver for one of the flanges14which are placed respectively therein and thus partially wrap around the end sections16B of the panels.

Disposed between the central sections16A of the metal panels16is a continuous wooden inner section18abutting the opposing central sections16A of the panels and abutting the flanges14. Wooden inner section18and flanges14are affixed together with the pair of panels16using adhesive applied to the abutting areas or other fasteners as will be shown in another embodiment below. Flanges14and wooden inner sections18are generally standard wooden framing members such as 2×4s, 2×6s, 2×8s, etc., and may be selected as needed to provide the required dimensions of the structural member. Likewise, panels16are fabricated in various dimensions to accommodate various combinations of flanges14and inner sections18. The resulting composite structural member10is thus stronger and more structurally stable than a similarly-sized member made entirely of wood and lighter and less expensive than a similarly-sized member made entirely of metal.

There are often applications in which the loading conditions are such that a continuous inner wooden section is not necessary. The embodiment shown inFIG. 2may be used in such cases. InFIG. 2, the composite structural member10includes a wooden inner section made up of a series of spaced-apart wooden members19disposed between the back-to-back central sections16A of the metal panels16. As seen inFIG. 2, the inner wooden members19extend generally parallel to the flanges14. Because of the spaced apart nature of the wooden members19, there is defined one or more voids21that extend through the web12. This embodiment demonstrates further the advantage of reduced weight to meet a particular need or load requirement.

There are situations in which no wooden inner section is required as shown inFIG. 3. In this embodiment the central sections16A of the pair of metal panels16abut directly. Web12is comprised entirely of metal, being made up of the central sections16A of the pair of metal panels16. In this particular embodiment metal screw fasteners20connect the central sections16A to each other and wood screw fasteners22connect the end sections16B of the panels16to the flanges14. It is appreciated that wood screw fasteners22can be used in the earlier embodiments ofFIG. 1andFIG. 2to connect the central sections16A to the continuous wooden inner section18or the spaced-apart inner wooden members19as well as the end sections16B to the flanges14. It is further appreciated that added structural integrity can be realized by the use of metal screw fasteners20and wood screw fasteners22in combination with adhesive materials placed between the various abutting surfaces.

FIGS. 5-8illustrate various bracket designs for securing the structural member10to an adjacent structure such as a floor structure. Viewing the design ofFIG. 5it is seen that there is provided a pair of metal brackets with each bracket indicated generally by the numeral50. In the example illustrated inFIG. 5, the metal brackets50attach the structural member10to an underlying structure such as a floor. It is appreciated that the same metal brackets50can be secured to the upper or opposite end of the structural member10for connecting to an overhead structure.

Metal bracket50includes a base52and an upstanding leg54. Base52is provided with an opening through which a bolt62extends. Disposed over the base52is an optional reinforcing plate60. A nut64is secured to the bolt62and functions to securely connect the metal bracket50to the underlying structure. Leg54includes a series of openings through which fasteners68extend. Fasteners68are secured into the web16of the structural member10. In the embodiment ofFIG. 5there is provided a notched-out portion66. The notched-out portion66is formed in the web16. This enables an installer or operator to gain access to the nut64for installing or removing the structural member10. The notched-out portion66would include a portion of the central section16A of one panel16and a portion of the wooden inner section18.

FIG. 6illustrates another embodiment of the structural member10and the metal bracket50. In this case the metal bracket50includes an additional leg56such that the metal bracket assumes a generally U-shape. That is, together the base52along with the two legs54and56form a U-shaped metal bracket. Bracket50is wrapped around the lower portion of the central sections16A of the web16. That is, the legs54and56are disposed outside of the central section16A and abut thereagainst. As seen inFIG. 6the U-shaped bracket50extends between the flanges14and end sections16B of the panels16. To facilitate the installation of the design shown inFIG. 6, the end portion of the structural member10that is inserted into the metal bracket50can be slightly indented to provide a space for the base52and the nut and bolt structures62and64.

The design ofFIG. 7is similar to the design shown inFIG. 5. One difference is that the metal bracket inFIG. 5includes a leg54which is disposed in a position such that it extends generally parallel with the central sections16A of the panels16. In the embodiment shown inFIG. 7, legs54are disposed transversely with respect to the central sections16A of the panels16. In this case, lower portions of the flanges14as well as portions of the end sections16B have been removed to form lower outside void areas for receiving the leg54of the brackets50. In the case of theFIG. 7design, the leg54is secured to a portion of the end sections16B of the panels16. As seen inFIG. 7a series of bolts or fasteners68extend into the end sections16B of the panels.

Turning toFIGS. 8A-8C, in this design the structural member10is provided with one or more tabs70that are turned to form a connector that connects to an adjacent structure. Tabs70include an opening72formed therein. The tabs70that project below the flanges14are spaced apart and can be turned as shown inFIG. 8Bto fit flush adjacent a floor or adjacent structure. A bolt62is projected upwardly from a support structure through the opening72in each tab70and a nut64is screwed down so as to secure the structural member10to the adjacent structure. Note in the examples shown inFIGS. 8A-8Cthere is provided three tabs70with the respective tabs being alternating. By being alternating it is meant that each succeeding tab70extends from the opposite central section16A of the panels16.

Like other embodiments, the web16may include notched-out portions66to gain access to the nut64. Further, in the embodiment shown in8C, the connecting structure is reinforced by a reinforcing plate60which is optional. The reinforcing plate60is sandwiched between the nut64and an underlying washer and the tabs70. Like the embodiments discussed above, the tabs70can project from opposite ends of the structural member10. In this case, the tabs are integral with the metal panels16and project outwardly at opposite ends from the central sections16A of the panels16.

Turning now to the application and use of the composite structural member10of the present invention and consideringFIG. 4, it is appreciated that a general structural wall section, generally denoted by the numeral30, containing a garage door opening32B may be framed using a plurality of composite structural members10of the present invention and, alternatively or additionally, also using the composite structural member10as a header. It is appreciated that in the process of construction, two columns, each comprised of the composite structural member10, can be installed on either side of the opening32B and the header thereafter placed atop the columns such that a portion of the load from the header is borne axially by each column. When used as a column in this application, the composite structural member10is oriented such that the web12and flanges14extend vertically. It is further appreciated that when used as a header in this particular application, the web12extends horizontally over the opening32B and the flanges14are oriented one above the other. Positioned thusly as a header, the composite structural member10acts to carry the loads above the garage door opening32B and transmit them to the supporting columns. It is further appreciated that because of the wood-metal nature of the composite structural member10, various wall surfaces and other wall attachments can easily be attached to the wood portions of the composite structural member10.

While not described in detail here, it is appreciated that the metal-wood composite structural member10of the present invention can be effectively used in any situation where beam or columnar load resistance is needed. Such situations include but are not limited to girders, joists, and rafters. Moreover, use of a composite structural member of the current invention in the place of one or more studs in a wall section can affect improved resistance to shear and buckling of the wall.

The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the scope and the essential characteristics of the invention. The present embodiments are therefore to be construed in all aspects as illustrative and not restrictive and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.