Patent Publication Number: US-2018038107-A1

Title: Reinforced composite structure useful as studs, joists, rafters and other structural and non-structural building components

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority under 35 U.S.C. §119(e) from the following U.S. provisional application: application Ser. No. 62/372032 filed on Aug. 8, 2016. That application is incorporated in its entirety by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a composite building member such as a stud that is reinforced with metal, steel, fiberglass, plastic or other reinforcing material. 
     SUMMARY OF THE INVENTION 
     The present invention entails a composite building member that is useful as a stud, joist, rafter or other structural or non-structural building component. In one embodiment, the composite building member is made up of concrete, wood fiber and fiberglass and includes a metal reinforcing structure embedded therein. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the stud of the present invention. 
         FIG. 2  is a longitudinal sectional view of the stud of the present invention. 
         FIG. 3  is a cross-sectional view of the stud of the present invention. 
         FIG. 4  is a longitudinal sectional view of a joist. 
         FIG. 5  is a cross-sectional view of the joist. 
         FIG. 6  is a perspective view of a rafter. 
         FIG. 7  is a cross-sectional view of the rafter. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     The present invention relates to a composite building member that is reinforced with metal, steel, fiberglass, plastic or other suitable material. The composite building member is a molded product that, in one embodiment, is made up of concrete (cement and sand), wood fiber and fiberglass. As noted above, a reinforcing structure is embedded in the molded building product. The resulting composite structure may be structural or non-structural in nature. 
     There are many uses for the composite building member discussed herein. The building member can be used as a stud, floor joist, ceiling joist, rafter, or any other component that is typically found in a wood building or structure or even found in a light steel frame structure. In one of the examples discussed herein, this new composite structure can be utilized to make component of a fence, including fence pickets and fence posts. 
     To form the molded product, the dry components, concrete, wood fiber and fiberglass are mixed with water or an aqueous solution. The resulting mixture is then placed in a mold after the reinforcing structure has been appropriately laid or positioned in the mold. A molding process ensues and this ultimately results in the production of a composite building member in accordance with the present invention. 
     Turning to the drawings,  FIGS. 1-3  show an example of the composite building member and this example constitutes a stud. A stud is specifically designed as a vertical member that forms a part of a wall. The stud in  FIGS. 1-3  is referred to generally by the numeral  20 . First, it should be appreciated that the size or dimensions of the stud  20  can vary. That is, the length, width and thickness of the stud  20  can vary. In this case, as discussed above, the stud is a molded product and is formed, in one example, by mixing concrete, wood fiber and fiberglass in water or an aqueous solution and then placing the mixture (composite slurry) in the mold. It is understood and appreciated that a reinforcing structure is placed in the mold such that after the composite building member is molded, the reinforcing structure is appropriately embedded therein. In one example, the dry constituents used to form the mixture comprise approximately 90% concrete, 6% wood fiber and 4% fiberglass. This can vary and other supplemental or filler materials can be added as desired. 
     The reinforcing structure for the exemplary stud can be constructed of metal, steel, fiberglass, plastic or other suitable materials that will lend an appreciable amount of strength to the stud. In the example disclosed herein, the reinforcing structure for the stud  20  is metal. There are various ways that an internal metal assembly or frame can be constructed and laid out in the stud.  FIGS. 1-3  simply show one example. In this case, two C-shaped parallel channels  22  extend along opposed edges of the stud and extend substantially the entire length of the stud. Each C-shaped channel  22 , shown in  FIG. 2 , includes a web  22 A, a flange  22 B and an angled return  22 C. See  FIG. 3 . These two C-shaped parallel channels  22  are interconnected on each side of the stud  20  by a series of horizontally extending and spaced apart transverse ties  24 . In this embodiment, the ties are also constructed of metal. Note that the ties are parallel to each other and that the ties extend between the returns  22 C of the C-shaped channels  22 . Various means can be utilized to connect the C-shaped channels  22  with the transverse ties  24 . In one case, the metal components can be connected together by fasteners, such as screws or bolts. In another embodiment, these steel components can be welded together. When the mixture of concrete, wood fiber, fiberglass and water are disposed in the mold, it follows that this mixture surrounds and encompasses the components that constitute the metal reinforcement. Of particular note is that this composite mixture will integrate into the internal areas defined by the C-shaped channels  22  and will essentially become locked therein once the molded stud  20  is produced. 
     In a preferred embodiment of the stud  20 , it is beneficial to provide a nailing surface or plate  21  at opposite ends of the stud. Typically, this nailing structure will extend across the opposed ends of the stud  20 . This will enable nails to be driven into this structure if required. In the case of the embodiment shown in  FIGS. 1-3 , the transverse ties  24  disposed about the extreme ends of the stud  20  can, in some cases, function as a nail receptor. 
     When the stud or other building component is reinforced with metal or steel, it is preferred to provide one or more utility passthroughs or openings  23  at various points along the length of the composite structure. This allows various utilities such as electric wiring, plumbing and a variety of other utilities to be threaded through these passthroughs without the need for drilling holes to accommodate these utilities. It should be pointed out that when these composite molded products are reinforced with metal or steel, they are not designed to be cut. In many cases, they are deemed structural members and should not be cut. 
     In the embodiment just discussed for the stud  20  and shown in  FIGS. 1-3 , the reinforcing structure is metal or steel. However, it is appreciated that the reinforcing structure can be plastic or fiberglass and if so, would generally be in a solid tubular form. This enables the stud  20  or other type of composite building member to be cut, drilled into or shaped as needed. 
     The stud, shown in  FIGS. 1-3 , again is just one example of how the composite structure described here can be employed. Composite structures according to the design and makeup just described can be designed and produced to serve as floor joists, ceiling joists, rafters and other structures in a building. 
       FIGS. 4 and 5  show a joist  40 . The joist is constructed in the same manner as the stud shown in  FIGS. 1-3  and discussed above. That is, the joist is made of up of a composite material. In one example, the composite material includes concrete and wood fibers. In another embodiment, the composite material may include concrete, wood fibers and fiberglass. The reinforcing structure and its orientation are shown in  FIG. 5 . It is essentially of the same design found in the stud shown in  FIGS. 1-3 . That is, the reinforcing structure includes two spaced apart C-shaped channels  22  that, in one embodiment, are constructed of metal. A series of ties  24  are interconnected between the C-shaped channels  22 . There is one noticeable difference in the joist shown in  FIGS. 4 and 5  from the stud shown in  FIGS. 1-3 . The joist includes opposed trim end portions  42 . These trim end portions occupy a small portion of the joist on each end. In one example, these trim end portions extend approximately 1¼ inch. Note that the reinforcing structure terminates short of the opposed ends of the joist. Where the metal reinforcing structure terminates in this example defines the trim end portion. Providing the trim end portion on the opposed ends of the joist enables the joist to be precisely cut to conform to a particular dimension. 
     Turning to  FIGS. 6 and 7 , there is shown therein a rafter  50 . The rafter conforms to the basic design of the stud shown in  FIGS. 1-3  with the exception that the rafter does not include the utility passthroughs. But for that exception, the basic design is the same in that it includes a composite material and a reinforcing structure which essentially comprises the opposed C-shaped channels  22  and the interconnecting ties  24 . 
     The term “joist” means a load carrying member extending horizontally across a floor or ceiling structure of a building. The term “rafter” means an elongated load bearing member found in a roof structure. 
     The present invention also includes a method of manufacturing a building member such as a stud, joist or rafter. The basic process entails mixing concrete and wood fibers with water to form a composite slurry. In some embodiments, the mixture may include concrete, wood fiber and fiberglass. This mixture constitutes a composite slurry. A mold is prepared and the reinforcing structure is placed in the mold as oriented in the drawings. The composite slurry is poured into the mold, embedding the reinforcing structure in the process. The mold is allowed to cure and dry and the composite building member is removed from the mold. 
     There are many advantages to the composite building structure or member discussed herein. First, the structure is resistant to rust and corrosion. It is also resistant to termites and fireproof. 
     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.