Abstract:
An extruded structural beam having a first member comprising rigid webbing interposed between a top flange and bottom flange. The top and bottom flanges of the first member each have a groove formed thereon for receiving a spline to secure screening material. Similarly, a second member having rigid webbing interposed between a top flange and bottom flange have a groove formed on the flanges for receiving a spline to secure screening material. The top and bottom flanges of both the first member and second member each further comprise opposing longitudinal channels for coupling the flanges so that a rectangular structural beam is formed. The outer surfaces of the flanges each further comprise a longitudinal slot so that a plurality of fasteners can be installed, through the longitudinal slots and flanges to secure the first member and second member together.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to structural beams, and more specifically to using a novel means of assembly and flange design to increase the strength, of a structural beam. 
         [0003]    2. Description of the Prior Art 
         [0004]    It is common for lightweight aluminum alloy beams to be used to construct the framework for a screened pool enclosure. The beams are typically assembled in the field from two separate members to form a hollow box beam. The distance that the aluminum beam can span over an open space without additional support is determined by the thickness, or gauge, of the aluminum. Another factor is dimensions of the beam. Although a beam with a larger cross section provides additional, strength and can span larger distances, a disadvantage to a larger beam is that it is not aesthetically pleasing, is heavy in weight making it more difficult to work with in the field and more expensive. 
         [0005]    There have been attempts to improve the prior art aluminum alloy beams to increase the strength without increasing the size and weight of the beams. However, one shortcoming of the prior art is that there is no interlocking relationship between the two separate members. Therefore, a weakness of the prior art beams is that the fasteners securing the flanges of the two members together are subject to high tension, which may cause the beam to fell under load. Accordingly, what is needed in the art is a beam that has interlocking flanges to increase the strength of the beam and to reduce the tension on the fasteners and possibility of local buckling. 
         [0006]    Another need exists in the art for the two separate members of the beam to act as one unit and to decrease the likelihood of local buckling under design loads. 
         [0007]    Another need exists in the art for a beam that increases span distances over the standard legacy beam shape in the industry. 
         [0008]    Another need exists in the art for a structural beam that that is lightweight and easy to assemble in the field. 
         [0009]    Another need exists in the art for an improved structural beam wherein the wall thickness of the beam is variable to meet deflection criteria in foe local, and state building codes. 
         [0010]    It is, therefore, to the effective resolution, of the aforementioned problems and shortcomings of the prior art that the present invention is directed. 
         [0011]    However, in view of the prior art at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how the identified needs could be fulfilled. 
       SUMMARY OF THE INVENTION 
       [0012]    This invention is an extruded structural beam comprising a first member having a first webbing interposed between a first top flange and a first bottom flange wherein said first top flange is disposed perpendicular to said first webbing and parallel to said first bottom flange; said first top flange having a longitudinal channel formed on a first lower surface of said first fop flange; said top flange having a first upper surface further comprising a first upper groove formed thereon for receiving a first upper spline; said first bottom flange having a longitudinal channel formed on a first lower surface of said first bottom flange; and said bottom flange further comprising a first lower groove for receiving a first lower spline; a second member having a second webbing interposed between a second top flange and a second bottom flange wherein said second top flange is disposed perpendicular to said second webbing and parallel to said second bottom flange; said second top flange further comprising a longitudinal channel formed on a second lower surface of said second top flange; said top flange having a second upper surface further comprising a second upper groove formed thereon for receiving a second upper spline; said second bottom flange having a longitudinal channel formed on a second lower surface of said second bottom flange; and said second bottom flange further comprising a second lower groove for receiving a second lower spline; said longitudinal channel of said first top flange removably coupled to said longitudinal channel of said second top flange and said longitudinal channel of said first bottom flange is removably coupled to said longitudinal channel of said second bottom flange so that a rectangular structural beam is formed; said first upper surface of said fop flange of said first member further comprising an upper longitudinal slot so that a plurality of fasteners can be installed through said upper longitudinal slot and through said top flange of said second member to secure said top flange of said first member and said top flange of said, second member. 
         [0013]    The improved structural beam provides increased strength of the beam through a novel means of assembly and flange design that when assembled has three overlying flange layers. The invention allows for greater spans to be bridged by the new beam using the assembly of two separate members with the new flange configuration that can be easily cut and joined together in the field thereby improving ease of installation and reducing costs. The trademark name for this invention is suggested to be the “Triple Flange Beam.” 
         [0014]    It is therefore a primary object of the invention to provide an improved structural beam that will be used in the construction of aluminum screen enclosures. 
         [0015]    Another object of the present invention is to employ similar aluminum alloys that are used in the construction of aluminum screen enclosures. 
         [0016]    Another object of the present invention is to provide an improved structural beam wherein, the wall thickness of the beam is variable to meet deflection criteria in the local and state building codes. 
         [0017]    Another object of the present invention is to provide an improved structural beam that has interlocking flanges to increase the strength of the beam. 
         [0018]    Another object of the present invention is to provide an improved structural beam with two separate members that act as one unit and to decrease the likelihood of local buckling under design loads. 
         [0019]    Another object of the present invention is to provide an improved structural beam that increases span distances over the standard legacy beam shape in the industry. 
         [0020]    Another object of the present invention is to provide an improved structural beam that is lightweight and easy to assemble in the field. 
         [0021]    These and other important objects, advantages, and features of the invention will become clear as this description proceeds. 
         [0022]    The present invention, accordingly, comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with, the accompanying drawings, in which; 
           [0024]      FIG. 1  is a partial perspective view showing a first embodiment of the beam of the present invention as assembled; 
           [0025]      FIG. 2  is a cross sectional view showing a first embodiment of the beam of the present invention; 
           [0026]      FIG. 3  is a cross sectional view showing a first member of the beam, in the first embodiment of the present invention; 
           [0027]      FIG. 4  is a partial perspective view showing a second embodiment of the beam of the present invention as assembled; 
           [0028]      FIG. 5  is a cross sectional view showing a second embodiment of the beam of the present invention; 
           [0029]      FIG. 6  is an exploded cross sectional, view showing a first member and strut of the beam in a second embodiment of the present invention; 
           [0030]      FIG. 7  is a partial perspective view showing a third embodiment of the beam of the present invention as assembled; 
           [0031]      FIG. 8  is a cross sectional view showing a third embodiment of the beam of the present invention as assembled; 
           [0032]      FIG. 9  is an exploded cross sectional view showing a first member and strut of the beam in the third embodiment of the present invention; 
           [0033]      FIG. 10  is a partial perspective view showing a fourth embodiment of the beam of the present invention as assembled; 
           [0034]      FIG. 11  is a cross sectional view showing a fourth embodiment of the present invention as assembled; and 
           [0035]      FIG. 12  is an exploded cross sectional view showing a first member and strut of the beam in the fourth embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0036]      FIG. 1  shows the new beam  100  is comprised of a first member  130  and a second member  120 . The beam  100  is shown assembled to form a rectangular hollow shape. Each member is a standard beam shape that is used in construction, of screen enclosures and extruded through a die process to various lengths. First member  130  and second member  120  are assembled in the field to form the new structural beam  100 . The materials used to make beam  100  are the same aluminum alloys that are used in the construction of aluminum, screen enclosures. The wall thickness of first member  130  and second member  120  will vary between each size change and are dependant on code requirements to meet deflection criteria in the local and state building codes. 
         [0037]    Referring now to  FIG. 2  and  FIG. 3 , a cross section of the beam  100  is shown including the coupling of the flanges. A longitudinal slot  125  on top flange  150  and longitudinal slot  127  on bottom, flange of second member  120  show where screws are used to secure first member  130  and second member  120  together. An architectural groove  129  is provided on bottom, flange of second member  120  and an architectural groove  132  is provided on the top flange of first member  130  that mirrors the groove that is formed when the top flanges and bottom flanges are assembled together. 
         [0038]    A rigid webbing  135  interconnects upper flange  150  and lower flange  140 . In cross sectional view, the first member is generally C-shaped. A longitudinal channel  142  is formed on the lower surface of the bottom flange  140 . Channel  142  allows for the opposing lower flange of the second member  120  to be inserted therein and be coupled together. Similarly, channel  152  is adaptable so that top flange of second member  120  is coupled to top flange  150  of first member  130 . As beam  100  is manufactured, for the aluminum screen enclosure industry, groove  154  is formed in top flange  150  to receive a spline (not shown) used, to secure screening material therein. 
         [0039]    In the preferred embodiment the structural beam is screwed together with fasteners on the top flange  150  and bottom flange  140  using sheet metal screws. A longitudinal slot is provided on the top flange  150  of first member  130  and on the bottom flange of second member  120  for the location of the fasteners. A key difference between the prior art and the present invention is that the tension load on the screws is greatly reduced by the novel design of the flanges of the present invention. Accordingly, the screws have higher efficacy in preventing the first member and second member from being pulled apart under a load. When beam  100  is assembled, the flanges of first member  130  and second member  120  are overlying one another and form three layers for superior strength quality of beam  100 . 
         [0040]    Referring now to  FIG. 4  shows a second embodiment of beam  400  assembled with first member  430  and second member  420 . A first planar strut  510  is inserted to first member  430  and a second planar strut  520  is inserted to second member  420 .  FIG. 5  and  FIG. 6  show the cross section of beam  400 . A rigid webbing  435  interconnects upper flange  450  and lower flange  440 . Top flange  450  and bottom flange  440  of first member  430  are identical to top flange  150  and bottom flange  140  of beam  100 . The difference is the addition of planar struts  510 ,  520 , which provide additional strength and resistance to the buckling of beam  400  under loads.  FIG. 6  shows how planar strut  510  is inserted to first member  430 , which is identical to die procedure to insert planar strut  520  to second member  420 . Planar strut  510  includes a small top flange  550  mat is positioned adjacent to the lower surface of top flange  450  of first member  430 . A small bottom flange  540  of planar strut  510  is positioned adjacent to the upper surface of bottom flange  440  of first member  430 . An upper protrusion  555  and lower protrusion  575  on planar strut  510  engages an opposing upper protrusion  455  and lower protrusion  475  on the inside surface of first member  430 . In addition, a track is interposed on planar stmt  510  between upper protrusion  555  and lower protrusion  575  to engage a T-shape projection on first member  430 . Once planar strut  510  is secured to first member  430 , the procedure is repeated to insert planar strut  520  to second member  420 . First member  430  and second member  420  are then assembled using top flange  450  and bottom flange  440 , which comprise longitudinal channels  452 ,  442 , respectively, and grooves  454 ,  444  for receiving a spline to secure screening material. 
         [0041]    Referring now to  FIG. 7  shows a third embodiment of beam  700  assembled with first member  730  and second member  720 . Similar to the second, embodiment described above, a first planar strut  810  is inserted to first member  730  and a second planar strut  820  is inserted to second member  720 .  FIG. 8  and  FIG. 9  show the cross section of beam  700 . A rigid webbing  735  interconnects upper flange  750  and lower flange  740 . Top flange  750  and bottom flange  740  of first member  730  are identical to top flange  150  and bottom flange  140  of beam  100 . The difference is the addition of planar struts  810 ,  820 , which provide additional strength and resistance to the buckling of beam  700  under loads. The difference between the second embodiment and the present embodiment is the attachment means of planar struts  810 ,  820  to first member  730  and second member  720 , respectively.  FIG. 9  shows how planar strut  810  is inserted to first member  730 , which is identical to the procedure to insert planar strut  820  to second member  720 . Planar strut  810  includes a small top flange  850  that is positioned adjacent to the lower surface of tap flange  750  of first member  730 , A small bottom flange  840  of planar strut  810  is positioned adjacent to the upper surface of bottom flange  740  of first member  730 . An upper track  855  and lower track  875  on planar strut  810  engages an opposing upper T-shape protrusion  755  and lower protrusion  775  on the inside surface of first member  730 . In addition, a track is interposed on planar stmt  810  between upper track  855  and lower track  875  to engage an opposing shape protrusion on first member  730 . Once planar strut  810  is secured to first member  730 , the procedure is repeated to insert planar strut  820  to second member  720 . First member  730  and second member  720  are then, assembled using top flange  750  and bottom flange  740 , which comprise longitudinal channels  752 ,  742 , respectively, and grooves  754 ,  744  for receiving a spline to secure screening material. 
         [0042]    Referring now to  FIG. 10  shows a fourth embodiment of beam  900  assembled with first member  930  and second, member  920 . Similar to die second and third embodiments described above, a first planar strut  910  is inserted to first member  930  and a second planar strut  915  is inserted to second member  920 .  FIG. 11  and  FIG. 12  show the cross section of beam  900 . A rigid webbing  935  interconnects upper flange  950  and lower flange  940 . Top flange  950  and bottom flange  940  of first member  930  are identical to top flange  150  and bottom flange  140  of beam  100 . The difference is the addition of planar struts  910 ,  915 , which provide additional strength, and resistance to the buckling of beam  900  under loads. The difference between the second and third embodiment and the present embodiment is the attachment means of planar struts  910 ,  915  to first member  930  and second member  920 , respectively.  FIG. 12  shows how planar stmt  910  is inserted to first member  930 , which is identical to the procedure to insert planar strut  915  to second member  920 . Planar stmt  910  includes a small top flange  980  that is positioned adjacent to the lower surface of top flange  950  of first member  930 . A small bottom flange  990  of planar strut  910  is positioned adjacent to the upper surface of bottom flange  940  of first member  930 . An upper protrusion  957  and lower protrusion  977  on planar strut  910  engages an opposing upper protrusion  955  and lower protrusion  975  on the inside surface of first member  930 . Once planar strut  910  is secured to first member  930 , the procedure is repeated to insert planar strut  915  to second member  920 . First member  930  and second member  920  are then assembled using top flange  950  and bottom flange  940 , which comprise longitudinal channels  952 ,  942 , respectively, and grooves  954 ,  944  for receiving a spline to secure screening material. 
         [0043]    The particular embodiments disclosed above and in the drawings are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown. It is therefore evident that die particular embodiments disclosed above may be altered, or modified and all such variations are considered within the scope and spirit of the invention. 
         [0044]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention, which as a matter of language, might be said to tall there between. 
         [0045]    Now that the invention has been described,