CA2309127A1 - Synthetic members as a replacement for lumber - Google Patents
Synthetic members as a replacement for lumber Download PDFInfo
- Publication number
- CA2309127A1 CA2309127A1 CA 2309127 CA2309127A CA2309127A1 CA 2309127 A1 CA2309127 A1 CA 2309127A1 CA 2309127 CA2309127 CA 2309127 CA 2309127 A CA2309127 A CA 2309127A CA 2309127 A1 CA2309127 A1 CA 2309127A1
- Authority
- CA
- Canada
- Prior art keywords
- synthetic
- length
- lumber
- synthetic member
- members
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 38
- 239000004033 plastic Substances 0.000 claims abstract description 24
- 229920003023 plastic Polymers 0.000 claims abstract description 24
- 239000000463 material Substances 0.000 claims abstract description 21
- 239000002131 composite material Substances 0.000 claims abstract description 17
- 239000011230 binding agent Substances 0.000 claims abstract description 9
- 239000011236 particulate material Substances 0.000 claims abstract description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 8
- 239000010959 steel Substances 0.000 claims description 8
- 239000002245 particle Substances 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 239000004677 Nylon Substances 0.000 claims description 3
- 239000011152 fibreglass Substances 0.000 claims description 3
- 229910002804 graphite Inorganic materials 0.000 claims description 3
- 239000010439 graphite Substances 0.000 claims description 3
- 229920001778 nylon Polymers 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 claims 2
- 238000005755 formation reaction Methods 0.000 claims 2
- 229920001169 thermoplastic Polymers 0.000 claims 2
- 239000004416 thermosoftening plastic Substances 0.000 claims 2
- 229920002994 synthetic fiber Polymers 0.000 description 8
- 238000000926 separation method Methods 0.000 description 3
- 238000004873 anchoring Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 239000010903 husk Substances 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- 235000017060 Arachis glabrata Nutrition 0.000 description 1
- 244000105624 Arachis hypogaea Species 0.000 description 1
- 235000010777 Arachis hypogaea Nutrition 0.000 description 1
- 235000018262 Arachis monticola Nutrition 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000009194 climbing Effects 0.000 description 1
- 230000002301 combined effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 229920001179 medium density polyethylene Polymers 0.000 description 1
- 239000004701 medium-density polyethylene Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 235000020232 peanut Nutrition 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/28—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of materials not covered by groups E04C3/04 - E04C3/20
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
- E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
- E04C5/02—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance
- E04C5/03—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance with indentations, projections, ribs, or the like, for augmenting the adherence to the concrete
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Rod-Shaped Construction Members (AREA)
Abstract
A synthetic member for use as a substitute for conventional lumber comprising a length of composite material formed from particulate material bound together with a plastic binder and having a generally rectilinear cross section corresponding to the cross section of the lumber for which it is to be substituted. The synthetic member is reinforced by one or more elongated reinforcing members formed of material having tensile strength. Each reinforcing member is securely embedded or and anchored in the plastic material of the synthetic member and extends the length thereof to provide longitudinal stability. For high load bearing capacity the synthetic member has at least one of such reinforcing members located adjacent each of the upper and lower edges thereof.
Description
SYNTHETIC MEMBERS AS A
REPLACEMENT FOR LUMBER
FIELD OF THE INVENTION
This application relates to the provision of synthetic members which form a substitute or replacement for conventional lumber such as two by fours, two by sixes, and two by Bights etc.
BACKGROUND OF THE INVENTION
Vast quantities of lumber are used in the construction industry for erecting all types of buildings and other structures. As a result, many of the forests having trees particularly suitable for conversion into desirable lumber are being depleted to the bane of the environmentalists. As a result, the price of quality lumber has been climbing while much of the lumber available is of low quality.
Even the best of wood is subject to shrinkage, warping, twisting 2 0 and rotting under exposure to heat, moisture and other adverse conditions.
Moreover, the load bearing capacity of lumber is limited.
It is the object of this invention to provide synthetic members to be used as a replacement for conventional lumber which members can be sawed, 2 5 cut, nailed and worked with in the same way as conventional lumber but which will be cheaper, lighter, stronger and have greater load bearing capacity than conventional lumber and will be free from subsequent shrinkage, warping, twisting and rotting.
SUMMARY OF THE INVENTION
The invention involves the provision of lengths of synthetic members to be used as substitutes for conventional lumber, the members being formed of composite material comprising particulate filler or waste material 3 5 bound together by a plastic binder with the composite material. The members are reinforced by one or more elongated reinforcing members formed of material having tensile strength which are securely embedded or anchored in the plastic material of the synthetic member and extend the length thereof to provide longitudinal stability. To give high load bearing capacity to the synthetic member at least one such reinforcing member is located adjacent each of the upper and lower edges of the synthetic member.
It will be understood that such synthetic members will be formed to provide the same cross sectional boundary dimensions as conventional two by fours, two by sixes, two by Bights or other conventional lumber which they are to replace.
According to a preferred embodiment of the invention, at least the wider faces of the synthetic members are provided with a plurality of longitudinal grooves therein extending the length thereof. Such grooving significantly reduces the amount of material required to produce the synthetic members while still providing enhanced structural strength over conventional correspondingly dimensioned lumber.
2 0 According to another preferred embodiment of the invention, the synthetic lumber member contains four longitudinal reinforcing members, one adjacent each corner thereof.
The reinforcing members of the invention are formed of material that exhibits tensile and likewise compressive strength and are such that they can be anchored in the plastic and will occupy a small proportion of the volume of synthetic members. Examples of such reinforcing members are deformed wire, or deformed strands of other suitable material such as fiberglass or graphite, or lengths of perforated roll form steel or metal perforated channels.
In accordance with another preferred form of the invention, the synthetic members have one or more bores extending throughout their length with the center of the one or more bores lying in the midpoint of the width of the members.
In accordance with another embodiment of the invention, the longitudinal grooves on opposite faces of the synthetic members are offset whereby such members can be interlocked together face to face to convert, for example, a two by four member into effectively a four by four member.
These and other features will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective partly broken away view of a length of a synthetic member having a high load capacity to be used as a substitute for a piece of two by four of conventional lumber.
Figure 2 is an end view on a reduced scale of the synthetic member shown in Figure 1;
Figure 3 is a broken away perspective view of a synthetic member 2 0 corresponding to the member of Figure 1 but dimensioned to serve as a substitute for a two by six piece of conventional lumber;
Figure 4 is a view similar to Figure 3 but showing a synthetic member dimensioned to serve as a two by eight piece of conventional lumber;
Figure 5 is a view similar to Figures 3 and 4 but dimensioned to serve as a substitute for a plank of conventional lumber.
Figure 6 is a broken away perspective view of a synthetic member 3 0 which, depending on its depth, corresponds to any one of the members shown in Figures 1 to 5 but employing a different form of reinforcements;
Figure 7 is a broken away perspective view showing a short portion of a modified form of a synthetic lumber member in accordance with the 3 5 invention;
REPLACEMENT FOR LUMBER
FIELD OF THE INVENTION
This application relates to the provision of synthetic members which form a substitute or replacement for conventional lumber such as two by fours, two by sixes, and two by Bights etc.
BACKGROUND OF THE INVENTION
Vast quantities of lumber are used in the construction industry for erecting all types of buildings and other structures. As a result, many of the forests having trees particularly suitable for conversion into desirable lumber are being depleted to the bane of the environmentalists. As a result, the price of quality lumber has been climbing while much of the lumber available is of low quality.
Even the best of wood is subject to shrinkage, warping, twisting 2 0 and rotting under exposure to heat, moisture and other adverse conditions.
Moreover, the load bearing capacity of lumber is limited.
It is the object of this invention to provide synthetic members to be used as a replacement for conventional lumber which members can be sawed, 2 5 cut, nailed and worked with in the same way as conventional lumber but which will be cheaper, lighter, stronger and have greater load bearing capacity than conventional lumber and will be free from subsequent shrinkage, warping, twisting and rotting.
SUMMARY OF THE INVENTION
The invention involves the provision of lengths of synthetic members to be used as substitutes for conventional lumber, the members being formed of composite material comprising particulate filler or waste material 3 5 bound together by a plastic binder with the composite material. The members are reinforced by one or more elongated reinforcing members formed of material having tensile strength which are securely embedded or anchored in the plastic material of the synthetic member and extend the length thereof to provide longitudinal stability. To give high load bearing capacity to the synthetic member at least one such reinforcing member is located adjacent each of the upper and lower edges of the synthetic member.
It will be understood that such synthetic members will be formed to provide the same cross sectional boundary dimensions as conventional two by fours, two by sixes, two by Bights or other conventional lumber which they are to replace.
According to a preferred embodiment of the invention, at least the wider faces of the synthetic members are provided with a plurality of longitudinal grooves therein extending the length thereof. Such grooving significantly reduces the amount of material required to produce the synthetic members while still providing enhanced structural strength over conventional correspondingly dimensioned lumber.
2 0 According to another preferred embodiment of the invention, the synthetic lumber member contains four longitudinal reinforcing members, one adjacent each corner thereof.
The reinforcing members of the invention are formed of material that exhibits tensile and likewise compressive strength and are such that they can be anchored in the plastic and will occupy a small proportion of the volume of synthetic members. Examples of such reinforcing members are deformed wire, or deformed strands of other suitable material such as fiberglass or graphite, or lengths of perforated roll form steel or metal perforated channels.
In accordance with another preferred form of the invention, the synthetic members have one or more bores extending throughout their length with the center of the one or more bores lying in the midpoint of the width of the members.
In accordance with another embodiment of the invention, the longitudinal grooves on opposite faces of the synthetic members are offset whereby such members can be interlocked together face to face to convert, for example, a two by four member into effectively a four by four member.
These and other features will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective partly broken away view of a length of a synthetic member having a high load capacity to be used as a substitute for a piece of two by four of conventional lumber.
Figure 2 is an end view on a reduced scale of the synthetic member shown in Figure 1;
Figure 3 is a broken away perspective view of a synthetic member 2 0 corresponding to the member of Figure 1 but dimensioned to serve as a substitute for a two by six piece of conventional lumber;
Figure 4 is a view similar to Figure 3 but showing a synthetic member dimensioned to serve as a two by eight piece of conventional lumber;
Figure 5 is a view similar to Figures 3 and 4 but dimensioned to serve as a substitute for a plank of conventional lumber.
Figure 6 is a broken away perspective view of a synthetic member 3 0 which, depending on its depth, corresponds to any one of the members shown in Figures 1 to 5 but employing a different form of reinforcements;
Figure 7 is a broken away perspective view showing a short portion of a modified form of a synthetic lumber member in accordance with the 3 5 invention;
Figure 8 is a broken away perspective view of another modified form of a synthetic lumber member;
Figure 9 is an end view of the synthetic lumber member of Figure 8 but on a reduced scale;
Figure 10 shows two synthetic lumber members corresponding to the members shown in Figures 8 and 9 shown in side by side interlocked relations.
Figures 11 and 12 are perspective views of still other modified forms of synthetic lumber according to the invention.
Figure 13 is a perspective view on an enlarged scale of a length of deformed wire which is used as a reinforcing member in accordance with the invention.
2 o DETAILED DESCRIPTION ACCORDING TO THE PREFERRED
EMBODIMENTS OF THE PRESENT INVENTION
With reference to Figure 1, there is shown a longitudinal member 1 of synthetic material to be used as a substitute or a replacement for a length of two by four of conventional lumber. The synthetic member 1 is formed as an extrusion or a molded product and comprises particulate material bound together by a plastic binder. Such particulate material may be selected from a wide range of materials or mixture thereof such as sawdust, ground cloth, paper, glass fibers, reground thermoset materials, fly ash, kiln dust, ground 3 0 peanut shells, rice husks, corn husks, or sawdust, or the like. The plastic binder used to encapsulate and bind the particles together may, for example, comprise reground or recycled low, medium and high density polyethylene, polypropylene, polyethylene terephthalate (PET), nylon, PVC, ABS.
Figure 9 is an end view of the synthetic lumber member of Figure 8 but on a reduced scale;
Figure 10 shows two synthetic lumber members corresponding to the members shown in Figures 8 and 9 shown in side by side interlocked relations.
Figures 11 and 12 are perspective views of still other modified forms of synthetic lumber according to the invention.
Figure 13 is a perspective view on an enlarged scale of a length of deformed wire which is used as a reinforcing member in accordance with the invention.
2 o DETAILED DESCRIPTION ACCORDING TO THE PREFERRED
EMBODIMENTS OF THE PRESENT INVENTION
With reference to Figure 1, there is shown a longitudinal member 1 of synthetic material to be used as a substitute or a replacement for a length of two by four of conventional lumber. The synthetic member 1 is formed as an extrusion or a molded product and comprises particulate material bound together by a plastic binder. Such particulate material may be selected from a wide range of materials or mixture thereof such as sawdust, ground cloth, paper, glass fibers, reground thermoset materials, fly ash, kiln dust, ground 3 0 peanut shells, rice husks, corn husks, or sawdust, or the like. The plastic binder used to encapsulate and bind the particles together may, for example, comprise reground or recycled low, medium and high density polyethylene, polypropylene, polyethylene terephthalate (PET), nylon, PVC, ABS.
The amount of the plastic binder to particulate material can vary over a wide range even down to about ten percent by weight of the member but preferably the plastic binder comprises from about forty percent to sixty percent by weight and the particulate material from about sixty percent to forty percent by weight of the member.
With reference to Figure 1 which represents a synthetic lumber member having a high load capacity, it will be seen that, while the cross sectional boundary dimensions of the member 1 will correspond to the 1 o nominal dimensions of a conventional piece of two by four lumber, the side faces are provided with grooves 2 extending longitudinally thereof throughout the length of the member to provide a series of spaced lands or bearing surfaces 3 which lie in a common plane.
The top and bottom edges of the member 1 when viewing it with its major dimension upright have central grooves 4 therein running the length thereof to provide the spaced lands or bearing surfaces 5 which lie in a common plane. It will be understood that the planes in which the lands 3 lie and the planes in which the lands 5 lie will be at right angles to each other.
Embedded in each corner of the synthetic member 1 is the reinforcing member 6 having a relatively high tensile strength. Suitable reinforcing members 6 comprise deformed steel wire having a diameter of the order of about 3/l6th of an inch. These reinforcing members give significantly 2 5 increased beam strength to the synthetic member 1 over and above that of conventional lumber as hereinafter more fully explained.
As illustrated in the enlarged view Figure 13, these deformed wires 6 provide a pattern of repeating recessed areas 6a along their length into which 3 o the composite plastic material flows to provide a positive anchoring effect between the composite material of the member 1 and the wires to preclude any relative longitudinal movement between the plastic and the wires.
Thus, with this anchorage between the composite plastic material of 3 5 the member 1 and the deformed reinforcing wires 6, these wires will prevent any separation of the bound together particles and will ensure the accuracy or stability of the lengthwise dimension of the member.
Thus any variation in the consistency of the composite material of the member 1 along its length will be canceled effectively giving the member 1 a homogeneity along its length.
Other reinforcing members extending the length of the synthetic member 1 which exhibit good tensile and compressive strength include deformed strands of suitable material such as fiberglass, nylon or graphite.
It will be understood that the provision of the grooves 2 and 4 reduces the amount of synthetic material required to, produce the lumber substitute while allowing the nominal dimensions of the synthetic lumber member 1 to equal that of conventional lumber.
It will also be understood that by forming the synthetic member 1 from the composite material described it will be free of warping, twisting and rotting and the intimate bonding between the synthetic material of the 2 0 member and, as explained, the anchored reinforcing wires 6 will eliminate longitudinal creep or shrinkage of the plastic material.
It will be understood that with the member 1 serving as a beam under loading with its major dimension upright the reinforcing wires 6 at the 2 5 top will be under compression while those at the bottom will be under tension.
Being anchored to the plastic by virtue of the flow of the plastic into the recessed areas 6a, these wires 6 resist bending of the member 1 itself while at the same time preventing any separation of the bound together particles of the composite material eliminating any problems from any inconsistencies in the 3 0 binding of the particles at different areas throughout the length of the member.
Figures 3, 4 and 5 correspond to Figure 1, the only difference being that the dimensions of the synthetic member have changed with the synthetic 3 5 member 7, Figure 3, being dimensioned to replace the conventional two by six lumber member. The synthetic member 8 of Figure 4 is dimensioned to replace the conventional two by eight lumber member and the synthetic member 9, Figure 5, is dimensioned to replace a conventional lumber plank.
These synthetic members 7, 8 and 9 have the same grooves 2 in the side faces presenting the spaced lands or bearing surfaces 3 as those of Figure 1, likewise they have the same groove 4 defining the bearing surfaces 5 as in Figure 1. Again, at each corner of the synthetic members 7, 8 and 9, there are provided deformed wires reinforcing members 6 as in Figure 1 which are embedded and anchored in the synthetic material of the members to extend throughout the length thereof.
Figure 6 is a broken away perspective view of a modified form of synthetic member generally designated at 10 which like Figure 1 has grooves 2 in the side faces thereof to provide spaced lands or bearing surfaces 3 and grooves 4 in the top and bottom surfaces to provide bearing surfaces 5.
Figure 6 is broken away to indicate that it may represent a substitute for conventional two by four lumber, two by six lumber etc.
2 0 In the case of Figure 6, the deformed reinforcing wires 6 of Figure 1 have been replaced by corrugated or roll form steel members 11 embedded in the synthetic material of the member 10 at the corners thereof to extend the length thereof. In this case, the corrugations of the steel members 11 are provided with holes 12 through which the synthetic material of the synthetic 2 5 member can flow in the forming operation. It will be understood that both the corrugations of the member and the holes 12 form recesses in which the plastic flows to provide a very strong and intimate bond or anchor between the roll form members 11 and the synthetic composite material of the member 10.
3 0 Figure 7 is a modified form of synthetic member designated at 13 which differs from Figure 1 only in that it has longitudinal bores 14 therethrough to further reduce the amount of material required in forming the member.
g _ Again, the synthetic member 13 is provided with the grooves 2 defining the spaced lands 3, grooves 4 defining the bearing surfaces 5 and reinforcing members 6 securely embedded in the synthetic material and extending the length of the member adjacent the corners.
Figures 8 and 9 show a modified synthetic member 15 in which the cross sectional configuration of the member varies from that of previous figures, namely in that the grooves 16 which provide the bearing lands 17 on one side of the member 15 are offset from the grooves 18 providing the bearing lands 19 on the opposite face of the member 15.
The top and bottom surfaces of the synthetic member 15 have central grooves 4' corresponding to the grooves 4 of member 1 and reinforcing members 6' corresponding to the members 6 of synthetic member 1 located at the corners thereof.
With this arrangement shown in Figures 8 and 9 a pair of synthetic members 15 can be interlocked together in side by side relation as illustrated in Figure 10 to provide a structural member having a width nearly twice the 2 0 width of the individual members 15.
Where very high beam loading capacity is the objective of the synthetic substitute lumber member, a longitudinal tensile strength, reinforcing member is employed at each corner of the member. However, it will be 2 5 appreciated that a single reinforcing members such as a length of deformed steel wire or roll form steel embedded in the composite material and extending at least substantially the length of the member, one centrally located adjacent the upper edge and one centrally located adjacent the lower edge of the member, will provide a lumber substitute with greatly increased load bearing 3 0 capacity than conventional lumber.
In this connection, Figure 11 discloses a length of synthetic lumber substitute designated at 20 which has the same configuration as the member 1 of Figure 1 but employs only 2 reinforcing members 6 in the form of elongated 3 5 deformed wires as illustrated in Figure 13.
_ g _ In the case of the member 20, one of the deformed wires 6 is located centrally of the width of the member 20 adjacent the upper edge thereof as defined by the upper lands 5.
The other deformed wire 6 is located centrally of the width of the member 20 adjacent the lower edge thereof as defined by the lower lands 5.
With the arrangement shown in Figure 11, when the synthetic lumber substitute member 20 is subject to loading, the anchored reinforcing deformed wire 6 adjacent the upper edge of the member will be subjected to compression forces while the anchored deformed wire 6 adjacent the lower edge of the member 20 will be subjected to tensional forces. The combined effect of the two reinforcing members 6 adjacent the upper and lower edges of the member 20 will effectively resist the loading force and flexure of the member.
Again, as discussed above, with the wires 6 anchored in the 2 o plastic material of the member 20 which enters the recessed areas 6a, there will be no slippage between the plastic material and the wires so that the wires preserve the longitudinal integrity and stability of the member 20 preventing particle separation at any point along the length of the member thereby providing a control factor which gives structural consistency or homogeneity 2 5 throughout of the length of the member.
It will be understood that where load capacity is not an important consideration that this aspect of the invention of providing longitudinal integrity and stability to a length of substitute lumber can be 3 0 achieved by a single reinforcing member such as the deformed wire 6' shown in broken outline in Figure 1, embedded in the plastic material of and extending the length of the substitute lumber, such reinforcing member being located centrally of the plastic material.
Figure 12 shows another modified form of a synthetic lumber substitute member designated at 21. Again, as in the case of the member shown in Figure 11, the configuration of the member 21 is the same as the member 1 in Figure 1 but with only two reinforcing members 22 embedded therein. In this case, the members 22 are in the form of channels having a series of openings 23 through the webs thereof which openings constitute recesses into which the plastic material can flow.
One of the channels 22 is located adjacent the upper edge of the member 21 as defined by the upper lands 5 while the other channel is located adjacent the lower edge of the member designated by the lower lands 5.
By the provision of the holes 23 in the reinforcing channels 22, the synthetic material of the member 21 will flow through these openings to provide an intimate anchoring of the channels with the plastic material throughout the length of the synthetic member 21.
The functioning of the embedded channels 22 with respect to their providing load bearing capacity and stability to the substitute lumber 2 0 member 21 is as described above in connection with Figure 11.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the scope of the appended claims.
With reference to Figure 1 which represents a synthetic lumber member having a high load capacity, it will be seen that, while the cross sectional boundary dimensions of the member 1 will correspond to the 1 o nominal dimensions of a conventional piece of two by four lumber, the side faces are provided with grooves 2 extending longitudinally thereof throughout the length of the member to provide a series of spaced lands or bearing surfaces 3 which lie in a common plane.
The top and bottom edges of the member 1 when viewing it with its major dimension upright have central grooves 4 therein running the length thereof to provide the spaced lands or bearing surfaces 5 which lie in a common plane. It will be understood that the planes in which the lands 3 lie and the planes in which the lands 5 lie will be at right angles to each other.
Embedded in each corner of the synthetic member 1 is the reinforcing member 6 having a relatively high tensile strength. Suitable reinforcing members 6 comprise deformed steel wire having a diameter of the order of about 3/l6th of an inch. These reinforcing members give significantly 2 5 increased beam strength to the synthetic member 1 over and above that of conventional lumber as hereinafter more fully explained.
As illustrated in the enlarged view Figure 13, these deformed wires 6 provide a pattern of repeating recessed areas 6a along their length into which 3 o the composite plastic material flows to provide a positive anchoring effect between the composite material of the member 1 and the wires to preclude any relative longitudinal movement between the plastic and the wires.
Thus, with this anchorage between the composite plastic material of 3 5 the member 1 and the deformed reinforcing wires 6, these wires will prevent any separation of the bound together particles and will ensure the accuracy or stability of the lengthwise dimension of the member.
Thus any variation in the consistency of the composite material of the member 1 along its length will be canceled effectively giving the member 1 a homogeneity along its length.
Other reinforcing members extending the length of the synthetic member 1 which exhibit good tensile and compressive strength include deformed strands of suitable material such as fiberglass, nylon or graphite.
It will be understood that the provision of the grooves 2 and 4 reduces the amount of synthetic material required to, produce the lumber substitute while allowing the nominal dimensions of the synthetic lumber member 1 to equal that of conventional lumber.
It will also be understood that by forming the synthetic member 1 from the composite material described it will be free of warping, twisting and rotting and the intimate bonding between the synthetic material of the 2 0 member and, as explained, the anchored reinforcing wires 6 will eliminate longitudinal creep or shrinkage of the plastic material.
It will be understood that with the member 1 serving as a beam under loading with its major dimension upright the reinforcing wires 6 at the 2 5 top will be under compression while those at the bottom will be under tension.
Being anchored to the plastic by virtue of the flow of the plastic into the recessed areas 6a, these wires 6 resist bending of the member 1 itself while at the same time preventing any separation of the bound together particles of the composite material eliminating any problems from any inconsistencies in the 3 0 binding of the particles at different areas throughout the length of the member.
Figures 3, 4 and 5 correspond to Figure 1, the only difference being that the dimensions of the synthetic member have changed with the synthetic 3 5 member 7, Figure 3, being dimensioned to replace the conventional two by six lumber member. The synthetic member 8 of Figure 4 is dimensioned to replace the conventional two by eight lumber member and the synthetic member 9, Figure 5, is dimensioned to replace a conventional lumber plank.
These synthetic members 7, 8 and 9 have the same grooves 2 in the side faces presenting the spaced lands or bearing surfaces 3 as those of Figure 1, likewise they have the same groove 4 defining the bearing surfaces 5 as in Figure 1. Again, at each corner of the synthetic members 7, 8 and 9, there are provided deformed wires reinforcing members 6 as in Figure 1 which are embedded and anchored in the synthetic material of the members to extend throughout the length thereof.
Figure 6 is a broken away perspective view of a modified form of synthetic member generally designated at 10 which like Figure 1 has grooves 2 in the side faces thereof to provide spaced lands or bearing surfaces 3 and grooves 4 in the top and bottom surfaces to provide bearing surfaces 5.
Figure 6 is broken away to indicate that it may represent a substitute for conventional two by four lumber, two by six lumber etc.
2 0 In the case of Figure 6, the deformed reinforcing wires 6 of Figure 1 have been replaced by corrugated or roll form steel members 11 embedded in the synthetic material of the member 10 at the corners thereof to extend the length thereof. In this case, the corrugations of the steel members 11 are provided with holes 12 through which the synthetic material of the synthetic 2 5 member can flow in the forming operation. It will be understood that both the corrugations of the member and the holes 12 form recesses in which the plastic flows to provide a very strong and intimate bond or anchor between the roll form members 11 and the synthetic composite material of the member 10.
3 0 Figure 7 is a modified form of synthetic member designated at 13 which differs from Figure 1 only in that it has longitudinal bores 14 therethrough to further reduce the amount of material required in forming the member.
g _ Again, the synthetic member 13 is provided with the grooves 2 defining the spaced lands 3, grooves 4 defining the bearing surfaces 5 and reinforcing members 6 securely embedded in the synthetic material and extending the length of the member adjacent the corners.
Figures 8 and 9 show a modified synthetic member 15 in which the cross sectional configuration of the member varies from that of previous figures, namely in that the grooves 16 which provide the bearing lands 17 on one side of the member 15 are offset from the grooves 18 providing the bearing lands 19 on the opposite face of the member 15.
The top and bottom surfaces of the synthetic member 15 have central grooves 4' corresponding to the grooves 4 of member 1 and reinforcing members 6' corresponding to the members 6 of synthetic member 1 located at the corners thereof.
With this arrangement shown in Figures 8 and 9 a pair of synthetic members 15 can be interlocked together in side by side relation as illustrated in Figure 10 to provide a structural member having a width nearly twice the 2 0 width of the individual members 15.
Where very high beam loading capacity is the objective of the synthetic substitute lumber member, a longitudinal tensile strength, reinforcing member is employed at each corner of the member. However, it will be 2 5 appreciated that a single reinforcing members such as a length of deformed steel wire or roll form steel embedded in the composite material and extending at least substantially the length of the member, one centrally located adjacent the upper edge and one centrally located adjacent the lower edge of the member, will provide a lumber substitute with greatly increased load bearing 3 0 capacity than conventional lumber.
In this connection, Figure 11 discloses a length of synthetic lumber substitute designated at 20 which has the same configuration as the member 1 of Figure 1 but employs only 2 reinforcing members 6 in the form of elongated 3 5 deformed wires as illustrated in Figure 13.
_ g _ In the case of the member 20, one of the deformed wires 6 is located centrally of the width of the member 20 adjacent the upper edge thereof as defined by the upper lands 5.
The other deformed wire 6 is located centrally of the width of the member 20 adjacent the lower edge thereof as defined by the lower lands 5.
With the arrangement shown in Figure 11, when the synthetic lumber substitute member 20 is subject to loading, the anchored reinforcing deformed wire 6 adjacent the upper edge of the member will be subjected to compression forces while the anchored deformed wire 6 adjacent the lower edge of the member 20 will be subjected to tensional forces. The combined effect of the two reinforcing members 6 adjacent the upper and lower edges of the member 20 will effectively resist the loading force and flexure of the member.
Again, as discussed above, with the wires 6 anchored in the 2 o plastic material of the member 20 which enters the recessed areas 6a, there will be no slippage between the plastic material and the wires so that the wires preserve the longitudinal integrity and stability of the member 20 preventing particle separation at any point along the length of the member thereby providing a control factor which gives structural consistency or homogeneity 2 5 throughout of the length of the member.
It will be understood that where load capacity is not an important consideration that this aspect of the invention of providing longitudinal integrity and stability to a length of substitute lumber can be 3 0 achieved by a single reinforcing member such as the deformed wire 6' shown in broken outline in Figure 1, embedded in the plastic material of and extending the length of the substitute lumber, such reinforcing member being located centrally of the plastic material.
Figure 12 shows another modified form of a synthetic lumber substitute member designated at 21. Again, as in the case of the member shown in Figure 11, the configuration of the member 21 is the same as the member 1 in Figure 1 but with only two reinforcing members 22 embedded therein. In this case, the members 22 are in the form of channels having a series of openings 23 through the webs thereof which openings constitute recesses into which the plastic material can flow.
One of the channels 22 is located adjacent the upper edge of the member 21 as defined by the upper lands 5 while the other channel is located adjacent the lower edge of the member designated by the lower lands 5.
By the provision of the holes 23 in the reinforcing channels 22, the synthetic material of the member 21 will flow through these openings to provide an intimate anchoring of the channels with the plastic material throughout the length of the synthetic member 21.
The functioning of the embedded channels 22 with respect to their providing load bearing capacity and stability to the substitute lumber 2 0 member 21 is as described above in connection with Figure 11.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the scope of the appended claims.
Claims (11)
1. A synthetic member for use as a substitute for conventional lumber comprising a length of composite material formed of particulate material bound together with a plastic binder, said member having a generally rectangular cross section in which each of its four sides presents a flat bearing surface formation across the width of the respective side with the bearing surface formations of adjoining sides being at right angles, said member having at least one tensile strength reinforcing member extending at least substantially the length thereof securely embedded in said composite material.
2. A synthetic member as claimed in Claim 1 in which one of its said four sides forms an upper surface and the opposite of said four sides forms a lower surface, said synthetic member having at least two reinforcing members securely embedded in the composite material thereof and extending the length thereof, one of said at least two reinforcing members being located adjacent the upper surface of synthetic member and another of said at least two reinforcing members being located adjacent the lower surface of said synthetic member.
3. A synthetic member as claimed in Claim 1 or 2 in which at least two opposed sides of said member have longitudinal grooves formed therein and extending the length thereof.
4. A synthetic member as claimed in Claim 1 or 2 in which each reinforcing member is formed to provide recesses along its length filled with said composite material.
5. A synthetic member as claimed in Claim 1, 2 or 4 in which said particulate material comprises particles of recycled material and said plastic binder comprises a recycled thermoplastic.
6. A synthetic member for use as a substitute for conventional lumber selected from one of two by four, a two by six, or a two by eight inch lumber, said member comprising a length of composite material formed from a particulate material bound together by a thermoplastic binder and having a generally rectangular cross section having a width corresponding to the width of one of a conventional two by four, two by six or two by eight and a depth selected to correspond to the depth of one of a two by four, a two by six, or a two by eight conventional lumber, said synthetic member having a plurality of parallel longitudinal grooves formed in each side defining the depth of said synthetic members and having securely embedded therein a longitudinal tensile strength reinforcing member extending the length thereof adjacent to each corner thereof.
7. A synthetic member as claimed in Claim 6 in which each of said reinforcing members is formed to provide recesses along its length which are filled with said composite material.
8. A synthetic member as claimed in Claim 6 or 7 having a central longitudinal groove in each side of said synthetic member which forms the width of said synthetic member.
9. A synthetic member as claimed in Claim 6 or 7 in which the grooves in one of said sides forming the depth of said synthetic member are offset from the grooves in the other corresponding side of said synthetic member, whereby two such synthetic members may be locked together in side by side relation.
10. A synthetic member as claimed in Claim 6 or 7 in which said reinforcing member at each of the corners of said synthetic member is selected from one of deformed strands of steel wire, fiberglass, graphite, nylon, or a length of roll form steel.
11. A synthetic member as claimed in Claims 1 or 2 in which each reinforcing member comprises a length of metal channel having a web provided with a series of holes therethrough.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2309127 CA2309127A1 (en) | 2000-05-23 | 2000-05-23 | Synthetic members as a replacement for lumber |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2309127 CA2309127A1 (en) | 2000-05-23 | 2000-05-23 | Synthetic members as a replacement for lumber |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2309127A1 true CA2309127A1 (en) | 2001-11-23 |
Family
ID=4166222
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2309127 Abandoned CA2309127A1 (en) | 2000-05-23 | 2000-05-23 | Synthetic members as a replacement for lumber |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2309127A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6872434B2 (en) * | 2002-10-04 | 2005-03-29 | Royal Group Technologies Limited | Lumber substitute member |
| EP1878845A3 (en) * | 2006-07-04 | 2015-04-01 | Thomas GmbH + Co. Technik + Innovation KG | Structural member |
-
2000
- 2000-05-23 CA CA 2309127 patent/CA2309127A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6872434B2 (en) * | 2002-10-04 | 2005-03-29 | Royal Group Technologies Limited | Lumber substitute member |
| EP1878845A3 (en) * | 2006-07-04 | 2015-04-01 | Thomas GmbH + Co. Technik + Innovation KG | Structural member |
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