Patent Publication Number: US-2005123701-A1

Title: Elongated structural member having a plastic sleeve and a filler composite material

Description:
RELATED APPLICATIONS  
      This application claims the benefit of Provisional Application No. 60/526,236, filed Dec. 3, 2003, the contents of which are incorporated by reference. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates to the use of ground rubber. More particularly, the present invention relates to a structural member with a sleeve made of a plastic and with a filler composite material having ground rubber as a constituent.  
     BACKGROUND OF THE INVENTION  
      Conventional structural members having their external surfaces made of wood, metal or concrete are known. However, a metal surface is subject to corrosion, a wooden surface is subject to rot or attack by wood-boring animals and insects, and a concrete surface is subject to stress fractures. As a result, there is a need in the art for a structural member that overcomes the problems associated with conventional structural members. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      Other objects and advantages of the invention will become apparent from a study of the specification and drawings in which:  
       FIG. 1A  depicts an end view of the sleeve of the present invention.  
       FIG. 1B  depicts a sectional view of the sleeve shown within  FIG. 1A  along section line  1 B- 1 B of  FIG. 1A .  
       FIG. 2A  depicts an end view of the sleeve filled with a filler composite material having a concrete binder.  
       FIG. 2B  depicts an end view of the sleeve filled with a filler composite material having a concrete binder shown within  FIG. 2A  along section line  2 B- 2 B of  FIG. 2A .  
       FIG. 3A  depicts an end view of the sleeve filled with a filler composite material having a concrete binder and rebar.  
       FIG. 3B  depicts a sectional view of the sleeve filled with a filler composite material shown within  FIG. 3A  along section line  3 B- 3 B of  FIG. 3A .  
       FIG. 4A  depicts an end view of the sleeve filled with a filler composite material having a resin binder.  
       FIG. 4B  depicts a sectional view of the sleeve filled with a filler composite material shown within  FIG. 4A  along section line  4 B- 4 B of  FIG. 4A .  
       FIG. 5A  depicts an end view of the sleeve having an end cap.  
       FIG. 5B  depicts a sectional view of the sleeve having an end cap shown within  FIG. 5A  along section line  5 B- 5 B of  FIG. 5A .  
       FIG. 6A  depicts an end view of the sleeve having an end plug.  
       FIG. 6B  depicts a sectional view of the sleeve having an end plug shown within  FIG. 6A  along section line  6 B- 6 B of  FIG. 6A .  
       FIG. 7A  depicts an end view of the sleeve having an end plate.  
       FIG. 7B  depicts a sectional view of the sleeve having an end plate shown within  FIG. 7A  along section line  7 B- 7 B of  FIG. 7A .  
    
    
      Throughout the drawing figures, like reference numerals will be understood to refer to like parts and components. The drawings are not drawn to scale.  
     DETAILED DESCRIPTION OF THE INVENTION  
      The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the invention will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the embodiment shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.  
      To provide a detailed discussion of a preferred embodiment of the present invention, reference is now made to the drawings.  
      Shown within  FIGS. 1A and 1B  is a sleeve ( 100 ) for the elongated structural member of the invention. As shown within  FIG. 1A , the casing ( 100 - 1 ) of the sleeve ( 100 ) surrounds a void ( 100 - 2 ). The sleeve ( 100 ) being an extruded hollow profile plastic sleeve is within the scope of the invention.  
      The casing ( 100 - 1 ) is composed of a plastic material. It is within the scope of the invention for this plastic material to be a high-density poly-ethylene (HDPE). Moreover, it is also within the scope of the invention for this plastic material to be from the group consisting of an acrylonitrile-butadiene-styrene (ABS), a low-density poly-ethylene (LDPE), a poly-ethylene teraphthalate (PETE), and any plastic resin.  
       FIG. 1A  shows the shape of this cross-section for the casing ( 100 - 1 ) as a circular shape. However, a shape of this cross-section for the casing ( 100 - 1 ) being from the group consisting of an elipse, a polygon, and any planer region bounded by a curve is also within the scope of the invention.  
      Also shown within  FIG. 1A  is an outer dimension (OD) of the sleeve ( 100 ). This outer dimension (OD) of the sleeve ( 100 ) ranges from 10 inches to 16 inches. The outer dimension (OD) of the sleeve ( 100 ) being uniform throughout the entire sleeve length (L) is within the scope of the invention. Alternatively, variation of the outer dimension (OD) of the sleeve ( 100 ) along the sleeve length (L) is also within the scope of the invention.  
      Further shown within  FIG. 1A , is the wall thickness (t) of the casing ( 100 - 1 ). This wall thickness (t) ranges from 0.75 inches to 1.5 inches. The wall thickness (t) of the casing ( 100 - 1 ) being uniform throughout the entire sleeve length (L) is within the scope of the invention. Alternatively, variation of the wall thickness (t) of the casing ( 100 - 1 ) along the sleeve length (L) is also within the scope of the invention.  
       FIG. 1B  also shows sectional view of the sleeve shown within  FIG. 1A  along section line  1 B- 1 B of  FIG. 1A . As shown within  FIG. 1B , the sleeve ( 100 ) has a length (L). This length (L) ranges from less than an inch to many feet. The cross-section of the casing ( 100 - 1 ) being uniform throughout the entire sleeve length (L) is within the scope of the invention. Alternatively, variation in shape of the cross-section for the casing ( 100 - 1 ) along the sleeve length (L) is also within the scope of the invention.  
       FIG. 2A  depicts an end view of the sleeve ( 100 ) filled with a filler composite material ( 10 ) having a concrete binder, and  FIG. 3A  depicts an end view of the sleeve ( 100 ) filled with a filler composite material ( 10 ) having a concrete binder and rebar ( 15 ). The void ( 100 - 2 ) of the sleeve ( 100 ) is filled with an admixture of a filler composite material ( 10 ) that includes a concrete binder and ground rubber, resulting in either the the elongated structural member shown in  FIGS. 2A and 2B  or the the elongated structural member shown in  FIGS. 3A and 3B .  FIG. 2B  depicts the sleeve ( 100 ) filled with a filler composite material ( 10 ) along section line  2 B- 2 B of  FIG. 2A , whereas  FIG. 3B  depicts the sleeve ( 100 ) filled with a filler composite material ( 10 ) along section line  3 B- 3 B of  FIG. 3A .  
      Specifically, the ground rubber and the concrete binder are combined together to form the filler composite material ( 10 ). The ground rubber used to form filler composite material ( 10 ) includes, but is not limited to, ground scrap tires, crumb rubber, chipped rubber, tire crumb, or the like. This ground rubber being from post-consumer scrap rubber that has been pounded, crushed, or ground into the ground rubber particles is within the scope of the invention. Post-consumer scrap rubber within the meaning of the invention is rubber material that has entered the stream of commerce as a consumer good or has entered the stream of commerce as incorporated within a consumer good. Moreover, this ground rubber being from post-industrial scrap rubber that has been pounded, crushed, or ground into the ground rubber particles is also within the scope of the invention. Post-industrial scrap rubber within the meaning of the invention is rubber material that is a byproduct of industrial processing in the form of rubber chips, rubber grind, rubber shavings, or factory scrap rubber. The grandular particle size for the ground rubber particles ranges from 0.125 inches to 0.5 inches. Use of Portland Cement to form the concrete binder for the filler composite material ( 10 ) is within the scope of the invention. Ten to twenty percent by volume of the filler composite material ( 10 ) is the concrete binder while eighty to ninety percent by volume of the filler composite material ( 10 ) is the ground rubber particles.  
      The filler composite material ( 10 ) is cast into the sleeve ( 100 ) and cured. When the filler composite material ( 10 ) is placed into the casing ( 100 - 1 ) of the sleeve ( 100 ), the void ( 100 - 2 ) is consumed by the filler composite material ( 10 ), as shown within  FIGS. 2A and 2B .  
      Alternatively, the addition of rebar ( 15 ), as shown within  FIGS. 3A and 3B  is also within the scope of the invention. In particular, rebar ( 15 ) is incorporated within the filler composite material ( 10 ). Rebar ( 15 ) is a solid-core steel bar with ridges. Rebar ( 15 ) either as a single solid-core steel bar extending axially along the length (L) of the sleeve ( 100 ) or as two or more solid-core steel bars extending axially along the length (L) of the sleeve ( 100 ) is also within the scope of the invention.  
      When a resin binder is used in place of a concrete binder, the void ( 100 - 2 ) of the sleeve ( 100 ) is filled with an admixture of a filler composite material ( 20 ) that includes ground rubber and the resin binder, resulting in the elongated structural member ( 5 ) shown in  FIGS. 4A and 4B .  FIG. 4B  depicts the sleeve ( 100 ) filled with a filler composite material ( 20 ) along section line  4 B- 4 B of  FIG. 4A . In particular, the ground rubber and the resin binder are combined together to form the filler composite material ( 20 ). The ground rubber used to form filler composite material ( 20 ) includes, but is not limited to, ground scrap tires, crumb rubber, chipped rubber, tire crumb, or the like. Post-consumer scrap rubber within the meaning of the invention is rubber material that has entered the stream of commerce as a consumer good or has entered the stream of commerce as incorporated within a consumer good. Moreover, this ground rubber being from post-industrial scrap rubber that has been pounded, crushed, or ground into the ground rubber particles is also within the scope of the invention. Post-industrial scrap rubber within the meaning of the invention is rubber material that is a byproduct of industrial processing in the form of rubber chips, rubber grind, rubber shavings, or factory scrap rubber. Steel components are absent from within the ground rubber particles. The granular particle size for the ground rubber particles ranges from 0.125 inches to 0.5 inches. The resin binder aids in the adhesion between the ground rubber particles. The use of a urethane binder as a resin binder is within the scope of the invention. Commercially available urethane binders sold by Uniroyal Chemical under the trademark name ROYALBOND™, or other commercially available urethane binders are also within the scope of the invention. ROYALBOND 675™ is an acceptable urethane binder. Other binders that aid in the adhesion between the ground rubber particles are also within the scope of the invention. Ten percent by volume of the filler composite material ( 20 ) is the resin binder while ninety percent by volume of the filler composite material ( 20 ) is the ground rubber particles.  
      The filler composite material ( 20 ) is cast into the sleeve ( 100 ) and cured. When the filler composite material ( 20 ) is placed into the casing ( 100 - 1 ) of the sleeve ( 100 ), the void ( 100 - 2 ) is consumed by the filler composite material ( 20 ), as shown within  FIGS. 4A and 4B .  
      Shown within  FIG. 5A  is an end view of the sleeve ( 100 ) having an end cap ( 200 ) disposed at a distal end ( 105 ) of the casing ( 100 - 1 ).  FIG. 5B  shows a sectional view of the sleeve ( 100 ) having an end cap ( 200 ) shown within  FIG. 5A  along section line  5 B- 5 B of  FIG. 5A . The end cap ( 200 ) is structurally adapted to seal the casing ( 100 - 1 ) at the distal end ( 105 ). The end cap ( 200 ) disposed at a distal end ( 105 ) of the casing ( 100 - 1 ) provides an obstruction between the filler composite material ( 30 ) and an environment that is external to the casing ( 100 - 1 ). The filler composite material ( 30 ) the filler composite material described hereinabove either as the filler composite material ( 10 ) or as the filler composite material ( 20 ). As shown within  FIG. 5B , the end cap ( 200 ) is in contact with the rim ( 110 ) of the casing ( 100 - 1 ). Securing the end cap ( 200 ) to the casing ( 100 - 1 ) thru the use of an adhesive resin is within the scope of the invention. Likewise, securing the end cap ( 200 ) to the casing ( 100 - 1 ) thru the use of any conventional mechanical fastener is also within the scope of the invention. While the end cap ( 200 ) is shown at one distal end ( 105 ) of the casing ( 100 - 1 ), having the end cap ( 200 ) at the other distal end ( 106 ) of the casing ( 100 - 1 ) is also within the scope of the invention.  
      Shown within  FIG. 6A  is an end view of the sleeve ( 100 ) having an end plug ( 300 ) disposed at a distal end ( 105 ) and in contact with an interior surface ( 115 ) of the casing ( 100 - 1 ).  FIG. 6B  shows a sectional view of the sleeve ( 100 ) having an end plug ( 300 ) shown within  FIG. 6A  along section line  6 B- 6 B of  FIG. 6A . The end plug ( 300 ) is structurally adapted to provide an obstruction between the filler composite material ( 30 ) and an environment that is external to the casing ( 100 - 1 ). The filler composite material ( 30 ) the filler composite material described hereinabove either as the filler composite material ( 10 ) or as the filler composite material ( 20 ). While the end plug ( 300 ) is shown within  FIG. 6B  at the distal end ( 105 ) of the casing ( 100 - 1 ), the end plug ( 300 ) disposed at a distal end ( 106 ) of the casing ( 100 - 1 ) or anywhere along the length (L) is within the scope of the invention. Securing the end plug ( 300 ) to the casing ( 100 - 1 ) thru the use of an adhesive resin is within the scope of the invention. Likewise, securing the end plug ( 300 ) to the casing ( 100 - 1 ) thru the use of any conventional mechanical fastener is also within the scope of the invention.  
      Shown within  FIG. 7A  is an end view of the sleeve ( 100 ) having an end plate ( 400 ) disposed at a distal end ( 105 ) of the casing ( 100 - 1 ).  FIG. 7B  shows a sectional view of the sleeve ( 100 ) having an end plate ( 400 ) shown within  FIG. 7A  along section line  7 B- 7 B of  FIG. 7A . The end plate ( 400 ) is structurally adapted to seal the casing ( 100 - 1 ) at the distal end ( 106 ). The end plate ( 400 ) disposed at a distal end ( 106 ) of the casing ( 100 - 1 ) provides an obstruction between the filler composite material ( 30 ) and an environment that is external to the casing ( 100 - 1 ). The filler composite material ( 30 ) the filler composite material described hereinabove either as the filler composite material ( 10 ) or as the filler composite material ( 20 ). As shown within  FIG. 7B , the end plate ( 400 ) and the casing ( 100 - 1 ) are formed as a single unitary member. An elongated structural member having both an end cap ( 200 ) described hereinabove along with the end plate ( 400 ) is within the scope of the invention. Moreover, an elongated structural member having both an end plug ( 300 ) described hereinabove along with the end plate ( 400 ) is also within the scope of the invention.  
      Benefits of the invention described herein include resistance to stains, rust, rot, weather, corrosion, and peeling. The elongated structural member of the invention also has excellent durability. When post-consumer scrap rubber or post-industrial scrap rubber is used as the ground rubber, rubber otherwise destined for collection in a landfill or for incineration is diverted and reused, thereby, reducing amount of resources that are wasted.  
      Uses for the invention described herein include, but are not limited to, synthetic lumber, utility poles, boat docks, dock bumper guards, sign posts, railroad ties, marine pilings, marine bulkheads, support posts, and guard rail posts.  
      The preceding description is intended to enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as is suited to the particular use contemplated. The preceding description has been presented only to illustrate and describe the invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the following claims.