System and method of constructing a composite assembly

A composite assembly includes a series of elongated layers joined lengthwise thereof. At least two of the elongated layers each have an upper elongated portion and a lower elongated portion secured together in an end-to-end relationship at a joint therebetween by a connector arrangement. The upper elongated portion is constructed of a wood material, and the lower elongated portion is constructed of a non-wood material.

FIELD OF THE DISCLOSURE

The present disclosure relates to a composite assembly for use in the construction industry. More specifically, the present disclosure relates to a composite assembly particularly constructed in a layered arrangement with wood and non-wood elongated members joined in an end-to-end relationship.

BACKGROUND

In the construction of buildings, outdoor structures or the like, it is often desirable to utilize a beam or column which includes a plurality of boards, rather than an integral post made from a single piece of building material such as wood. Many embodiments of composite assemblies use one or more connectors to connect the plurality of component boards into the composite assembly. The composite assembly made from a plurality of boards can serve as a less expensive substitute for integral posts made from a single piece of wood, which can be quite expensive. It is not uncommon for building materials to increase exponentially in cost for every increase in length or width of the building material piece.

It is known to provide a composite assembly comprised of a series of elongated layers secured together lengthwise thereof with each layer including an upper elongated support member joined to a lower elongated ground-engaging member at a joint by a connector device. In such a composite assembly, the upper elongated member is normally constructed of a non-treated wood, and the lower elongated member is typically fabricated of a treated wood. Such treated wood is infused with a chemical, such as chromated copper arsenate (CCA), to prevent the natural process of decay of the ground-engaging wood. While such a composite assembly is acceptable in commercial building application, the Environmental Protection Agency (EPA) has banned the use of wood as used in the ground-engaging lower portion of the composite assembly for most residential use.

BRIEF DISCLOSURE

Therefore, Applicant has developed a composite assembly which is compliant with EPA regulations for use in residential application, and which is disclosed herein. The composite assembly is adapted for use as a support column in a building structure, and is comprised of a series of layers joined together lengthwise thereof. At least two of the elongated layers each include an upper elongated portion and a lower elongated portion secured together in an end-to-end relationship at a joint therebetween by a connector arrangement. The upper elongated portion is constructed of a first material comprised of wood, and the lower elongated portion is constructed of a second material comprised of a material other than wood, such as plastic.

In one exemplary embodiment, the lower elongated portions are embodied in separate, integrally formed segments. In another exemplary embodiment, the lower elongated portions are jointly formed together in a unit.

In yet another exemplary embodiment, the composite assembly is adapted for use as a support column in a building structure, and is comprised of a series of layers joined together lengthwise thereof. At least two of the elongated layers each include an upper elongated portion and a unitary lower assembly secured together in an end-to-end relationship at a joint therebetween by a connector arrangement. The upper elongated portion is constructed of a first material comprised of wood, and the unitary lower assembly is constructed of a second material comprised of a material other than wood, such as plastic. Each joint between the elongated upper portion and the unitary lower assembly is staggered at different heights relative to one another.

DETAILED DESCRIPTION

Dual sided connectors and composite assemblies including dual sided connectors are disclosed herein. The dual sided connectors can be used to interconnect a member of building material such as wood or wood composite timbers or boards in order to produce beams, columns, headers, trusses, or any other composite assemblies for use in the construction of buildings or the like. Embodiments of the dual sided connector can include a base plate with a plurality of teeth extending outwardly from the base plate. The dual sided connector can be disposed between layers or plies of building material so that it bridges an inner portion of the building material. When this assembly is compressed together, the teeth engage the building material and are embedded in the building material. Thus, building material members are spliced together to form the composite assembly.

Composite assemblies formed using connector plates are economical replacements for the use of integral or one piece wooden beams or columns in building construction. The ability of a composite assembly to be formed of smaller, and therefore cheaper, building material stock allows for the creation of a composite assembly of similar dimensions and strength of an integral beam, at a fraction of the cost. Various patterns and orientations for the teeth of the connectors are known and typically include teeth that enter a wooden component member parallel to the wood grain or perpendicular to the wood grain. However, it has been determined that these tooth alignments are undesirable, and an improved tooth arrangement is needed. Connector teeth that enter the wood parallel to the wood grain promote splitting of the wood along the wood grain, while teeth that enter the wood perpendicular to the wood grain are often flattened upon insertion into the wood and therefore show reduced ability to be secured into the wood.

FIG. 1depicts an embodiment of a dual sided connector10. The dual sided connector10comprises a base plate12. The base plate12may be of a galvanized steel; however, the type of material for the base plate12should not herein be limited to galvanized steel, but may also include any other suitable material that would be recognized by one skilled in the art. A plurality of teeth including a first tooth18and a second tooth20extend outwardly from the base plate12. The first tooth18and the second tooth20form a tooth pair22.

Referring toFIG. 3, the base plate12further includes a first surface24and a second surface26. The first tooth18and second tooth20form a tooth pair22that extends outwardly from the first surface24of the base plate12. A third tooth28and a fourth tooth30form a tooth pair32that extends outwardly from the second surface26of the base plate12. Thus, tooth pair22extends in an opposite direction from the base plate12than tooth pair32extends from the base plate12.

In an embodiment, the outwardly extending teeth may be formed by die cutting the teeth from the material of base plate12through the use of a punching mechanism using a die to cut the teeth from the base plate12. In these embodiments, the die may be formed to produce twisted teeth, as will be disclosed in greater detail herein as the die passes through the base plate12. The punching mechanism may be arranged such that a separate die or set of dies is used to punch the teeth extending in each direction from the base plate12. These teeth may be punched simultaneously or separately. As a result of the die cutting, some embodiments may include an opening34formed in the base plate12(as depicted inFIGS. 1 and 2) where the material for each of the teeth was removed. Each tooth pair22is cut by a single die cut resulting in a single opening34between the first tooth18and the second tooth20of the tooth pair22.

It is understood that while for the sake of simplicity, first surface24, first tooth18, second tooth20, and tooth pair22are described in further detail herein, the description is similarly applicable to the second surface26, third tooth28, fourth tooth30, and tooth pair32, projecting from the opposite side of base plate12.

Referring to the embodiment of the dual sided connector10depicted inFIGS. 5 and 6, both the first tooth18and the second tooth20of tooth pair22project outwardly from the base plate12in the same direction from the first surface24. The first tooth18and second tooth20extend generally parallel to each other and generally perpendicular to the base plate12. The first tooth18and second tooth20are trapezoidal in shape with a base end36connected to the base plate12and an outwardly extending end38away from the first surface24. The outwardly extending end38of the first tooth18terminates in a tip40. The outwardly extending end38of the second tooth20terminates in a tip42. The tip40and tip42may simply come to points, but also may be manufactured so as to be chiseled in profile. The tip40of the first tooth18matches in height, the tip42of the second tooth20.

The tip42of the second tooth20is offset from the tip40of the first tooth18, as seen inFIG. 6. Teeth18and20each have a vertical axis52as will be described in further detail herein. The tips40and42may be offset from each other at opposite sides of the vertical axis52of their respective tooth. Thus tip40is offset to one side of vertical axis52and tip42is offset to the other side of vertical axis52. The offset of tips40and42of this embodiment provide particular advantages when the dual sided connector10is used to join two or more members of building material. One advantage is that the offset nature of tip40and tip42help to evenly balance each building material member on the connector10and promote even insertion of the teeth (18,20) into the building material members. Additionally, the tips (40,42) reduce the force necessary to penetrate the building material member and help to reduce any instances of splitting in the building material members as a result of the insertion of teeth into the building material members.

The offset tips40and42provide an additional advantage in manufacturing the dual sided connector10. In this embodiment, a die used to cut the tooth pair22can cut both the first tooth18and the second tooth20at the same time as the offset tips (40,42) of the first and second teeth (18,20) interlace in the die pattern. Thus only a single die cut is needed to cut both the first tooth18and the second tooth20including the tips (40,42) of the teeth. Therefore, in some embodiments, the dual sided connector10may have the additional benefit of providing the presently disclosed features with a simplified manufacturing process to make the dual sided connector10.

Still referring toFIGS. 5 and 6, the first tooth18and the second tooth20are oriented in the tooth pair22such that each tooth has an elongated profile44and a narrow profile46. In the tooth pair22, the elongated profiles44of the teeth are parallel and face each other. The elongated profiles44of the teeth promote gripping of the building material upon insertion and the narrow profiles46of the tooth promote insertion of the tooth into the building material and reduced splitting of the building material.

Referring toFIGS. 1 and 2, the dual sided connector10is arranged with a plurality of tooth pairs22oriented in a series of rows48. The rows48are aligned on the base plate12perpendicular to the elongated profile44(SeeFIG. 6) of the teeth of the tooth pair22. The plurality of tooth pairs22in each of the rows48all extend outwardly from the first surface24of the base plate12in the same direction. The dual sided connector plate10is further arranged with a plurality of rows50comprising tooth pairs32extending outwardly from the second surface26of the base plate12and in the opposite direction from tooth pairs22. Rows50are aligned on the base plate12in an alternating fashion with rows48alternatingly extending from the base plate12in the opposite direction. The alternating rows48and50of outwardly extending tooth pairs22and tooth pairs32in opposite directions promote an even distribution of the tooth pairs (22,32) extending from the first surface24and the second surface26of the base plate12. Therefore, the teeth in rows48extend from the base plate12in one direction and the teeth in rows50extend from the base plate12in the opposite direction. Some embodiments of the dual sided connector10may feature rows48and50in which the tooth pairs (22,32) in alternating rows (48,50) are offset, as depicted inFIGS. 1 and 2. The offset of opposing tooth pairs further improve the uniformity of the distribution of the teeth in the dual sided connector10and may promote additional support and structural strength within the base plate12.

Now referring toFIGS. 4-6, as mentioned previously, the first tooth18and the second tooth20of the tooth pair22each comprise a vertical axis52perpendicular to the base plate12. The first tooth18and the second tooth20are twisted about this axis. Similar or matching twists may be placed in both the first tooth18and the second tooth20of the tooth pair22. The twist angle54is generally between an angle of zero and 45 degrees from normal. The twist angle54may be any angle within this range. In one embodiment, the angle is 20 degrees or less. In another embodiment, the angle is between 10 and 15 degrees. In another embodiment, the angle may be between zero and 10 degrees. In a further embodiment, the angle may be three degrees. The twists in the teeth (18,20) may be clockwise or counter clockwise, and may all be in the same direction for all of the teeth. In alternative embodiments, the twists in the teeth (18,20) may be different for different individual teeth, or may be coordinated between tooth pairs22, rows48,50of tooth pairs, or on each side of the dual sided connector10. It should be understood that in embodiments wherein the tooth pair22is cut by a die, the die may be modified in order to produce the desired angle of the twist, or the orientation of the twist for the teeth in the tooth pair22.

The feature of the twisted teeth of the dual sided connector10provide advantages in use and implementation of the dual sided connector10over previous connector designs and implementations as will be described in further detail herein.

Referring toFIGS. 7 and 8, the dual sided connector10may be used to construct a composite assembly56such as a beam, post, column, truss, or the like. The composite assembly56may be formed from a plurality of elongated wood boards58. In the embodiment disclosed in further detail herein the composite assembly56comprises a plurality of wood boards58; however, it is understood that other building material members comprising not only wood and wood composite boards, but engineered boards, synthetic composite materials, or any other suitable building materials as recognized by one skilled in the art may be used. The wood boards58may be of varying lengths, but each has face60on opposite sides of the board58and each board58terminates in an end62.

Wood boards58are disposed in an end-to-end relationship wherein the end62of one board58abuts an end62of a second board58. The ends62of the wood boards58meet to form a joint68. The one or more wood boards58aligned in the end-to-end relationship form a first layer64of the composite assembly56. The composite assembly56may comprise a plurality of layers, depicted here as a second layer72and a third layer74. Each of the layers (64,72,74) are made up of at least one wood board58and it should be understood that the composite assembly56may be made from any number of layers, from two or more.

The first layer64and the second layer72are aligned in a face-to-face relationship wherein the faces60of the wood boards58in the first layer64are arranged to contact the faces60of one or more wood boards58of the second layer72. At least one of the layers, such as first layer64, includes a plurality of wood boards58. The joint68between the wood boards58of the layer64is secured using one side of the dual sided connector10as disclosed herein to connect the wood board58to the other wood board58across the joint68.

In implementation, the composite assembly56is formed by aligning a dual sided connector10across the joint68of two boards58in the first layer64. In one embodiment, the dual sided connector10is aligned so that half of the tooth pairs32on the second surface26of the dual sided connector10are arranged over one of the wood boards58of the first layer64and the other half of the tooth pairs32on the second surface26of the dual sided connector10are arranged over the other wood board58of the first layer64. Thus, the dual sided connector10is evenly arranged over the joint68.

The second layer72includes at least one wood board58and is arranged over the top of the dual sided connector10. A single wood board58of the second layer72is placed in contact with the teeth extending from the first surface24of the dual sided connector10. The composite assembly56is arranged in this manner so that the dual sided connector10does not cover a joint68between two boards58in both the first layer64and the second layer72. The staggering of the joints68across the layers (64,72,74) promotes strength in the fully constructed composite assembly56. Each staggered joint68of one layer is matched with a face of a single wood board58of the next layer. Therefore, each dual sided connector10of the composite assembly56attaches three boards together.

The wood boards58are constructed such that a wood grain70runs generally along the length of each of the boards58. In a further aspect of the disclosure, the dual sided connector10is aligned over the joint68between the boards58such that the dual sided connector10is square with each of the boards58and evenly disposed over the boards58of the joint68. Furthermore, the dual sided connector10is arranged with the elongated profile44of each of the teeth of the dual sided connector aligned generally parallel with the wood grain70of the boards58. A similar alignment exists between the dual sided connector10and the wood board58of the second layer72, aligned in face-to-face relationship with the first layer64. Therefore, the elongated profile44of the teeth of the dual sided connector10is also aligned generally parallel with the wood grain70of the board58of the second layer72.

While it is understood that the teeth of the dual sided connector10are twisted as disclosed above and the grain of the wood boards58is generally variable, and therefore the twisted teeth will generally not be perfectly parallel with the grain70of the wood board58, because the twist angle54of each of the teeth is less than 45 degrees and the wood grain70runs generally parallel to the length of each of the boards58, if the dual sided connector10is square with the board58, there will be a preferred orientation in which the elongated profile44of the teeth of the dual sided connector10are more generally parallel with the wood grain70and an alternative, less favored orientation in which the elongated profile44of the teeth of the dual sided connector10are more generally perpendicular to the wood grain70of the boards58. The general alignment of the elongated profile44of each of the teeth of the dual sided connector with the wood grain70of the boards58improves the resulting penetration of the teeth into the wood boards58as will be described in further detail herein.

It is understood that in alternative embodiments, the dual sided connector10may be aligned such that the elongated profile44at the base of the teeth is generally parallel with the wood grain70. Alternatively still, the elongated profile44of each of the teeth at the tip (40,42) may be aligned generally parallel with the wood grain70.

Once the wood boards58and the dual sided connector10have been arranged as disclosed, a compressive force is applied to the wood boards58of the composite assembly56. This presses the dual sided connector10into the wood boards58of both of the layers. The alignment of the teeth of the dual sided connector10in general alignment with the wood grain70of the wood boards58as well as the tips (40,42) of the teeth of the dual sided connector10and the offset orientation of the tips (40,42) of the teeth (18,20) in each tooth pair22of the dual sided connector10promote the penetration of the teeth into the wood boards58. This allows for the dual sided connector10to embed into the wood boards upon compression of the composite assembly56such that the dual sided connector10is not visible in the completed composite assembly56. Rather, the teeth and the base plate12of the dual sided connector10are embedded between the layers (64,72,74) of the wood boards58. The twisting of each of the teeth of the dual sided connector10helps to limit any splitting of the wood boards58along the grain of the wood70as the teeth enter the wood offset from parallel with the wood grain70. Yet, the twist angle is acute enough such that the teeth do not enter the wood substantially perpendicular to the wood grain70and therefore desirable penetration is achieved into the wood boards58. The dual sided connector10exhibits an improved gripping ability as the twisted teeth are more resistant to loosening over time than straight teeth

Embodiments of the composite assembly56may include multiple layers to the composite assembly56, which are represented by layer74, in order to create the desired width of the composite assembly56. In these embodiments, one or more additional dual sided connectors10may be used to connect the layers of the composite assembly56. In some embodiments, the outside layer (i.e. second layer72) on either side of the composite assembly56comprises a single integral board running the length of the composite assembly56. One or more interior layers (i.e. first layer64or third layer74) may comprise a plurality of boards58in each layer extending to the desired total length of the composite assembly56. This presents the advantage of reducing the cost of the composite assembly56by using shorter, and therefore less expensive boards58on the interior of the composite assembly56, while the aesthetics of the composite assembly56are promoted through the continuous outside facing boards. This eliminates visible joints68in the faces of the composite assembly56and promotes the illusion that the composite assembly56is a single piece of material.

The composite assembly56therefore presents the advantages of having an improved aesthetic appearance as the improved penetration of the dual sided connectors10hide the dual sided connectors10in the interior of the composite assembly56by embedding the dual sided connectors10into the boards58of the composite assembly56. Also, the orientation of the twisted teeth of the dual sided connector reduces the likelihood of splitting the boards58of the composite assembly56and thus more consistently produces an aesthetically pleasing composite assembly56that is free of splits, cracks, or other defects due to the connector plates. The composite assembly56further exhibits the advantage of being stronger than previous composite assemblies as the improved penetration of the teeth and the twisted orientation of the teeth provide a tighter hold between the dual sided connector10and the boards58of the composite assembly56. Additionally, the reduced splitting experienced with the disclosed dual sided connector further improves the overall strength and integrity of the composite assembly56as splits or other flaws may create weak spots within the composite assembly56that are aggravated in load bearing use.

It should be understood from the disclosure herein that many modifications as would be recognized by one skilled in the art may be made to the embodiments disclosed herein and will be considered to be within the scope of this disclosure. In this respect, the dual sided connector as disclosed herein may be constructed to any dimension as one skilled in the art may deem suitable for the desired implementation and use in constructing a composite assembly. In embodiments wherein the dual sided connector is to be embedded within the composite assembly and thus not visible in the finished composite assembly, it is understood that the dimensions of the dual sided connector would include those that are smaller than the dimensions of the wood boards of which the composite assembly is comprised. It is further understood that the composite assembly may include a plurality of layers of wood boards connected by a plurality of dual sided connectors in order to form a composite assembly having greater dimensions than those of the single wooden boards.

The present disclosure contemplates a composite assembly76such as may be used as a vertical support column in a residential building structure.

Referring toFIGS. 9 and 10, the composite assembly76is comprised of a series or plurality of opposing elongated layers78,80,82joined together lengthwise thereof. Each of the layers78,80,82includes an upper elongated portion in the form of an elongated member84, and a lower elongated portion in the form of an elongated member86. The upper and lower elongated portions84,86are secured together in an end-to-end relationship at joints88by connector arrangements or connectors10as previously described above. Top ends of the upper elongated portions84are typically used for supporting a superstructure of a building structure. Bottom ends of the lower elongated portions86are embedded securely beneath a ground surface G. Each of the elongated layers78,80,82are joined together along opposed interior faces by the connectors10at the joints88as well as at other locations spaced apart from and above the joints88.

In accordance with the present disclosure, the upper elongated portions84are constructed of a first material comprised of wood. In contrast, the lower elongated portions86are constructed of a second material comprised of a material other than wood. One example of a non-wood material to be used is plastic; however, it should be understood that the second material is not limited exclusively to plastic, and that use of other non-wood materials in the lower elongated portions86is contemplated as desired.

In the embodiments shown inFIG. 9, the upper elongated portions84form an upper assembly92constructed of single elongated member of wood, exemplarily untreated wood. A lower assembly90is constructed of the lower elongated portions86which are single members of a non-wood material. It should be understood that the elongated portions84,86may alternatively be constructed of multiple elongated members joined together suitably by connectors10. For example, upper elongated portions84may include more than one elongated member while lower elongated portions86may remain fabricated of single elongated members.

As described above, in the embodiment ofFIG. 9, the lower assembly90is formed of elongated portions86embodied in individual elongated members formed separately and individually from one another. In the embodiment ofFIG. 10, the lower assembly90is formed together as a single unitary structure of non-wood material.

In the representative composite assembly76ofFIG. 9, the combined length of the elongated layers78,80,82is substantially equal. For example, each layer78,80,82has a total length of twenty feet with a width of six inches and a depth of two inches. Layer78has an upper elongated portion84which is twelve feet in length, and a lower elongated portion86which is eight feet in length. Layer80has an upper elongated portion84and a lower elongated portion86which are each ten feet in length. Layer82has an upper elongated portion84which is fourteen feet in length, and a lower elongated portion86which is six feet in length. In this example, the joints88secured by the connectors10are staggered which promotes strength in the fully constructed composite assembly76. Additional configurations and dimensions of the composite assembly76are envisioned by the disclosure. For example, one or more of the layers78,80,82may be elongated in a single elongated member constructed of plastic or another non-wood material throughout its length. At least two of the elongated layers78,80,82have upper elongated portions84comprised of wood, and lower elongated portions86comprised of a non-wood material.

FIGS. 11-15illustrate a further embodiment of a composite assembly94such as may be used as a vertical support column in a building structure. The building structure may be a residential, commercial, or industrial building structure. The composite assembly94is comprised of a series of opposing elongated layers96,98,100joined together lengthwise thereof. Each of the layers96,98,100includes an upper elongated portion in the form of an elongated member102which is typically constructed of a first material comprised of wood, such as untreated wood. The upper elongated portions102together collectively form an upper assembly104. Top ends of the upper elongated portions102are typically used for supporting a superstructure of a building.

The composite assembly94also includes a unitary lower assembly106having a flat lower end107embedded securely beneath the ground surface G. The lower assembly106is constructed of a second material which is a non-wood material such as plastic, although other non-wood materials besides plastic may be used. The lower assembly106has a central region108which is provided with reinforcing structure in the form of a pair of spaced apart reinforcing rods110as best seen inFIGS. 13 and 14. The rods110are typically embodied as rebar constructed of one-half inch diameter steel which extend longitudinally through the central region108of the lower assembly106from a flat upper end111thereof to and beneath the flat lower end107thereof for embedding in the ground. Each of the rods110is preferably formed with bends112extending inwardly a similar distance, exemplarily one foot, from the upper and lower ends111,107, respectively, of the lower assembly106to facilitate the securement of the rods110within the lower assembly106such as during formation of a plastic or other non-wood lower assembly106. In an exemplary embodiment wherein the lower assembly106is a plastic composite material, the lower assembly106may be cast or molded around the rods110. In such embodiments, the bends112may function to keep the rods110from separating from the lower assembly106during use.

In an exemplary embodiment, the reinforcing rods110further extend out from the lower end107in projections109. The projections109may exemplarily bend or angle away from one another and the generally parallel orientation of the reinforced rods110when extending through the lower assembly106. In an embodiment, the projections109extend in a generally perpendicular direction from the rest of the reinforcing rod110and extend in such direction beyond a width of the lower assembly106. As depicted inFIG. 11, the lower assembly106may be secured within a footing F beneath the ground surface G. In an example, the footing F is a poured concrete footing. The projections109extend into the footing F and further facilitate to secure the lower end107of the lower assembly106in position beneath the ground G.

At least two of the elongated layers96,98,100have upper elongated portions102comprised of wood, and the lower assembly106comprised of a non-wood material, such as a solid plastic core.

The upper elongated portions102and various height portions of the lower assembly106are joined together in an end-to-end relationship at joints114,116,118by connector arrangements formed by respective pairs of connector plates120,122, splice plates124,126and deflection plates128,130. The joints114,116,118are staggered in height relative to one another as in the composite assembly76ofFIGS. 9 and 10to promote strength in the composite assembly94. The joint114is formed between a flat lower end132of the upper elongated portion102of layer98and the flat upper end111of the central region108of the lower assembly106. The joint116is formed between a flat lower end134of the upper elongated portion102of layer96and an inwardly extending ledge136formed on the lower assembly106. The joint118is formed between a flat lower end138of the upper elongated portion102of the layer100and an inwardly extending ledge140of the lower assembly106.

The plates120,122define a first plate structure, take the form of dual-sided connectors10as described above and are used to join the elongated layers96,98,100along opposed interior faces thereof. In the examples shown, each of the plates120,122have equal lengths with the plates120,122lying parallel to each other and with their upper and lower ends in staggered relationship relative to one another. The plate120and plate122extend the lengths of respective sides of the central region108, the joint114continue along the elongated layer98. Elongated layer96is secured to the plate120. Elongated layer100is secured to the plate122. As best depicted inFIG. 12, the plate120is positioned across the joint114and has a lower end142which extends to and terminates at the joint116. It is to be recognized that in alternative embodiments, the plate120terminates shortly before the joint116. The plate122is positioned across the joint114and has a lower end144which extends to and terminates at the joint118. It is to be recognized that in alternative embodiments, the plate122terminates shortly before the joint118.

The splice plates124,126define a second plate structure and are preferably configured with single-sided connectors formed with teeth146only on an inwardly facing surface of a base plate147. The plates124,126are of equal length, lie parallel to one another and have upper and lower ends which are in staggered relationship relative to one another. The plate124is centered lengthwise across the joint116along exterior side faces of the layer96and the lower assembly106. A screw fastener148is passed through an upper end of the plate124, the layer96and the plate120, and is secured in the central region108of the lower assembly106to anchor the plate124on the composite assembly94such that the teeth146penetrate the exterior side faces of the layer96and the lower assembly106above and below the joint116. This further serves to secure the flat lower end138to the lower assembly106, and particularly to the central region108. The plate126is centered lengthwise across the joint118along exterior side faces of the layer100and the lower assembly106. A screw fastener150is passed through the plate126, the layer100and the plate122, and is secured in the central region108of the lower assembly106beneath the joint116. Another screw fastener152is passed beneath screw fastener150through the plate126, the layer100and the plate122, and is secured in the central region108of the lower assembly106. The screw fasteners150,152fix the plate126on the composite assembly94such that the teeth146penetrate the exterior side surfaces of the layer100and the lower assembly106above and below joint118. This further serves to service the float lower end134to the lower assembly106, and particularly to the central region.

The deflection plates128,130as best seen inFIG. 14define a third plate structure. The deflection plates128,130are similar to single-sided connector plates124,126and are formed with teeth similar to teeth146on only an inwardly facing surface of the plates128,130. The plates128,130are exemplarily of equal length and lie parallel to one another. Embodiments of the deflection plates128,120have respective upper and lower ends as well as side edges which are aligned with one another. The plates128,130are both centered lengthwise across the joint118, and are suitably fixed such as by applying a suitable force causing the teeth to be retained in the front and back surfaces of the layers96,100and the lower assembly106. In the example shown, the upper ends of the plates128,130extend above the joint116, and the lower ends of the plates128,130extend beneath the joint118. The width of the plates128,130extend substantially across the width of the composite assembly94.

FIGS. 16-19depict a still further embodiment of a lower assembly160as may be used in connection with embodiments of the assemblies as presently disclosed. It will be recognized that like reference numerals are used inFIGS. 16-19as in other previously described figures to denote like structures. This is done for the purpose of conciseness and to highlight features shown inFIGS. 16-19. It will be recognized that various combinations of features of the embodiments as disclosed in the present application may be used while remaining within the scope of the present disclosure. In an exemplary embodiment, at least a portion of the lower assembly160includes at least four reinforcing rods162. As best depicted inFIGS. 16,17, and19in an area between the lower end107and the upper end111, and particularly below ledges136and140, two reinforcement rods162angle away from the center of the lower assembly160and run parallel to one another along a portion of the length of the lower assembly160. In an exemplary embodiment, the center of the lower assembly160is approximated by the center region108. In an exemplary manufacture of an exemplary embodiment as disclosed herein, the plastic and/or composite material of the lower assembly160may exemplarily be cast or molded about the reinforcing rods162.

FIG. 17is an enlarged view of a portion ofFIG. 16as denoted by line17-17inFIG. 16. InFIG. 17, the reinforcing rods162angle away from a rod upper portion164, which is exemplarily aligned along a center of the lower assembly160and center region108. In the embodiment depicted, the reinforcing rods162angle away at a 45 degree angle. However, it will be recognized that this angle may be within a variety of other angles including 20 degrees, 70 degrees or other angles therebetween. Additionally the angles may be between 10-80 degrees or other angles. In one embodiment, one of the reinforcing rods162is an elongated rod166that extends the entire length of the lower assembly160, and may exemplarily end at the lower end in the projections109. The elongated rods166thus make up the upper rod portion164. A support rod168connected at connecting points170, which may exemplarily be end welds, to the elongated rod166and extend within at least a portion of the lower assembly160. The support rod168may end at connection point170at a lower portion172of the elongated rod166.FIG. 18is a sectional view taken along line19-19and depicts the two reinforcing rods162extending within the center region108.FIG. 19is a sectional view taken along line19-19and depicts four reinforcing rods162extending within the lower assembly160. In an exemplary embodiment, the reinforcing rods162as depicted inFIG. 19may be located % inch from the exterior sides of the lower assembly160, although this is not intended to be limiting. In still further embodiments, one or more of the reinforcing rods162may include one or more bends (not depicted) such as exemplarily depicted inFIG. 13and described above. In another embodiment (not depicted), both rods continue through the center region as a rod pair. In a still further embodiment, all four of the reinforcing rods may extend as projections109out from the lower end107.

This written description uses examples to disclose various embodiments including the best mode, and also to enable any person skilled in the art to make and use these embodiments. The patentable scope is defined by the claims and may extend to include other examples not explicitly listed that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claim, or if they include equivalent elements with insubstantial differences from the literal languages of the claims.

Various alternatives and embodiments are contemplated as being within the scope of the following claims, particularly pointing out and distinctly claiming the subject matter of the present disclosure.