CA2660655A1 - Composite building components and method of making same - Google Patents

Composite building components and method of making same Download PDF

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Publication number
CA2660655A1
CA2660655A1 CA002660655A CA2660655A CA2660655A1 CA 2660655 A1 CA2660655 A1 CA 2660655A1 CA 002660655 A CA002660655 A CA 002660655A CA 2660655 A CA2660655 A CA 2660655A CA 2660655 A1 CA2660655 A1 CA 2660655A1
Authority
CA
Canada
Prior art keywords
building component
web
composite building
caliper
composite
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.)
Granted
Application number
CA002660655A
Other languages
French (fr)
Other versions
CA2660655C (en
Inventor
Mark A. Ruggie
Brian Bonomo
Lemuel Lee Braddock
Toplica Koledin
Bei-Hong Liang
Steven K. Lynch
Kathleen Nemivant
Beverly Pearce
Mark Allen Weldon
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Masonite Corp
Original Assignee
Individual
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from PCT/US2000/008520 external-priority patent/WO2000058581A1/en
Application filed by Individual filed Critical Individual
Publication of CA2660655A1 publication Critical patent/CA2660655A1/en
Application granted granted Critical
Publication of CA2660655C publication Critical patent/CA2660655C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

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
    • E04C3/12—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of wood, e.g. with reinforcements, with tensioning members
    • E04C3/16—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of wood, e.g. with reinforcements, with tensioning members with apertured web, e.g. trusses
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • 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
    • E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
    • E04C3/291—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures with apertured web
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/026—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of plastic
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3411—Dimpled spacer sheets
    • E04C2002/3422—Dimpled spacer sheets with polygonal dimples
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3444—Corrugated sheets
    • E04C2002/3455—Corrugated sheets with trapezoidal corrugations
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3472—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets with multiple layers of profiled spacer sheets

Abstract

A composite building component includes a non-planar molded composite web having two outer zones and two angled zones wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones, and a flange disposed on an outer surface of an outer zone. A method of providing a composite building component also is disclosed.

Claims (54)

WHAT IS CLAIMED IS
1 A composite building component, comprising (a) a non-planar molded composite web having a first outer zone, a second outer zone. and two angled zones, each of said zones having a caliper, and each of said zones having inner and outer surfaces, wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones, and (b) a flange disposed on an outer surface of said first outer zone.
2 The composite building component of claim 1 wherein the caliper of one outer zone is less than the caliper of the angled zones
3. The composite building component of claim 1 wherein the caliper of one outer zone is at least about equal to the caliper of the angled zones.
4 The composite building component of claim 1 wherein the caliper of the angled zones tapers from one outer zone to the adjacent outer zone.
The composite building component of claim 1 further comprising a radiused intersection between one surface of an angled zone and one surface of an outer zone.
6 The composite building component of claim 5 wherein the caliper of the web gradually changes from an angled zone to an outer zone via said radiused intersection.
7. The composite building component of claim 1 wherein a depth of draw of the non-planar molded composite web is greater than the caliper of any zone.
8. The composite building component of claim 1 wherein said non-planar molded composite web has an at least substantially uniform density.
9. The composite building component of claim 1 wherein the density of said non-planar molded composite web at an outer zone is at least about 75% of the density of said non-planar molded composite web at an angled zone.
10. The composite building component of claim 1 wherein the density of said non-planar molded composite web at a first outer zone is at least about 75% of the density of said non-planar molded composite web at a second outer zone.
11. The composite building component of claim 1 wherein at least a portion of a surface of an outer zone has a texture.
12. The composite building component of claim 1 wherein said non-planar molded composite web comprises OSB.
13. The composite building component of claim 1 wherein said outer zones and angled zones define at least one channel.
14. The composite building component of claim 1 comprising a second flange disposed on an outer surface of said second outer zone.
15. The composite building component of claim 1 comprising an end block.
16. The composite building component of claim 1 comprising a second non-planar molded composite web having two outer zones and two angled zones, each of said zones having a caliper, and each of said zones having inner and outer surfaces, wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones.
17. The composite building component of claim 16 wherein at least one outer zone of said second non-planar molded composite web is aligned with an outer zone of the first non-planar molded composite web.
18. The composite building component of claim 1 wherein the web includes a flattened shoulder between one surface of an angled zone and one surface of an outer zone.
19. The composite building component of claim 1 wherein said web comprises at least one cavity depending from and connected to a major plane of said web.
20. A composite building component, comprising:
(a) a web having at least one channel defined by a first outer zone, a second outer zone, and at least two angled zones, each of said zones having a caliper, and each of said zones having inner and outer surfaces;
(b) a first flange joined to said web at an outer surface of the first outer zone;
(c) a second flange joined to said web at an outer surface of the second outer zone; wherein the width of the building component, measured in a direction parallel to a channel, is not greater than the thickness of the building component, said thickness measured as a distance between parallel outer surfaces of the flanges.
21. The composite building component of claim 20 wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones.
22. A composite building component comprising:
a non-planar, molded array of wood strands defining a web panel having a caliper and having first and second undulating principal surfaces, said first and second principal surfaces providing an alternating pattern of first and second sets of ridges extending parallel to each other and oppositely disposed with respect to a center line of said web panel, adjacent ones of said ridges in said first set being connected to intermediate ones of said ridges in said second set by sloped walls; and the caliper of said web panel between said first and second principal surfaces being different in the vicinity of at least one of said first and second sets of ridges as compared to said sloped walls.
23. The composite building component of claim 22 wherein the caliper of at least one of said first and second sets of ridges is less than the caliper of the walls.
24. The composite building component of claim 22 wherein the caliper of at least one of said first and second sets of ridges is at least about equal to the caliper of the sloped walls.
25. The composite building component of claim 22 wherein the caliper of said sloped walls is tapered.
26. The composite building component of claim 22 further comprising a radiused intersection between a ridge and a sloped wall on at least one principal surface.
27. The composite building component of claim 26 wherein the caliper of the web panel gradually changes from a sloped wall to a ridge via said radiused intersection.
28. The composite building component of claim 22 wherein a depth of draw of the web panel is greater than the caliper of the panel at any location.
29. The composite building component of claim 22 wherein said web panel has an at least substantially uniform density.
30. The composite building component of claim 22 wherein the density of said web panel at a ridge is at least about 75% of the density of said web panel at a sloped wall.
31. The composite building component of claim 22 wherein the density of said web panel at a first ridge is at least about 75 %
of the density of said non-planar molded composite web at a second ridge.
32. The composite building component of claim 22 wherein at least a portion of a principal surface at a ridge has a texture.
33. The composite building component of claim 22 wherein said web panel comprises OSB.
34. The composite building component of claim 22 wherein said ridges and sloped walls define at least one channel.
35. The composite building component of claim 22 comprising a flange disposed on a principal surface in the vicinity of a ridge.
36. The composite building component of claim 22 comprising an end block.
37. The composite building component of claim 22 cmprising a flattened shoulder between a ridge and a sloped wall.
38. The composite building component of claim 22 comprising a second non-planar, molded array of wood strands defining a second web panel having a caliper and having first and second undulating principal surfaces, said first and second principal surfaces providing an alternating pattern of first and second sets of ridges extending parallel to each other and oppositely disposed with respect to a center line of said second web panel, adjacent ones of said ridges in said first set being connected to intermediate ones of said ridges in said second set by sloped walls; and the caliper of said second web panel between said first and second principal surfaces being different in the vicinity of at least one of said first and second sets of ridges as compared to said sloped walls.
39. The composite building component of claim 38 wherein at least one ridge of said second web panel is aligned with a ridge of the first web panel.
40. A method of producing a composite building component, said method comprising the steps of:
(a) forming a mat comprising a wood-based material;
(b) providing the mat in a die set, said die set having a non-planar configuration with at least two outer zones and at least two angled zones;
(c) closing the die to form a die gap, wherein the die gap at at least one of the outer zones differs from the die gap at the angled zones, (d) consolidating said mat under pressure and heat to form a molded composite web; and (e) joining said web with at least one flange;
to form the composite building component
41. The method according to claim 40 wherein the wood-based material comprises wood strands.
42. The method according to claim 40 wherein the die gap at one outer zone is less than the die gap at the angled zones.
43. The method according to claim 42 wherein the die gap at one outer zone is at least about equal to the die gap at the angled zones.
44. The method according to claim 40 wherein the surface area of the molded composite web is up to about 75 % greater than the surface area of the mat.
45. The method according to claim 44 wherein the surface area of the molded composite web is about 15% to about 25% greater than the surface area of the mat.
46. The method according to claim 40 wherein said molded composite web has at least one channel defined by a first outer zone, a second outer zone, and at least two angled zones, wherein said flange of step (e) is joined at an outer surface of said first outer zone, and further comprising the steps of:
(f) joining said web with a second flange at an outer surface of said second outer zone; and (g) dividing the product of step (f) in a direction perpendicular to a channel;
to produce the composite building component.
47. A composite building component produced according to the method of claim 40.
48. A method of producing a composite building component comprising the steps of:
(a) forming a mat comprising an array of wood strands;
(b) providing the mat in a die set, said die set having a non-planar configuration with first and second die surfaces;
(c) closing the die to form a die gap, wherein the die gap provides an alternating pattern of first and second sets of ridges extending parallel to each other and oppositely disposed with respect to a center line of said die set. wherein adjacent ones of said ridges in said first set are connected to intermediate ones of said ridges in said second set by sloped walls formed by the die gap, and wherein the die gap between the first and second die surfaces is different in the vicinity of at least one of the ridges as compared to said sloped walls;

(d) consolidating the mat under pressure and heat to form a molded composite web panel; and (e) joining the web with at least one flange, to form the composite building component.
49. The method according to claim 48 wherein the die gap at one ridge -s less than the die gap at said sloped walls.
50. The method according to claim 49 wherein the die gap at one ridge is at least about equal to the die gap at the sloped walls.
51. The method according to claim 48 wherein the surface area of the molded composite web panel is up to about 75 % greater than the surface area of the mat.
52. The method according to claim 51 wherein the surface area of the molded composite web panel is about 15 % to about 25 % greater than the surface area of the mat.
53. The method according to claim 48 wherein said molded composite web panel has at least one channel defined by a first ridge, a second ridge, and at least two sloped walls, wherein said flange of step (e) is joined at a first principal surface of said first set of ridges, and further comprising the steps of:
(f) joining said web panel with a second flange at a second principal surface of said second set of ridges; and (g) dividing the product of step (f) in a direction perpendicular to a channel, to produce the composite building component.
54. A composite building component produced according to the method of claim 48.
CA2660655A 2000-03-30 2000-10-05 Composite building components and method of making same Expired - Fee Related CA2660655C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
PCT/US2000/008520 WO2000058581A1 (en) 1999-03-31 2000-03-30 Composite building components, and method of making same
US09/538,766 2000-03-30
US09/538,766 US6511567B1 (en) 1999-03-31 2000-03-30 Composite building components and method of making same
USPCT/US00/08520 2000-03-30
CA002406837A CA2406837C (en) 2000-03-30 2000-10-05 Composite building components, and method of making same

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
CA002406837A Division CA2406837C (en) 2000-03-30 2000-10-05 Composite building components, and method of making same

Publications (2)

Publication Number Publication Date
CA2660655A1 true CA2660655A1 (en) 2001-10-11
CA2660655C CA2660655C (en) 2011-12-20

Family

ID=26680178

Family Applications (3)

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CA002406837A Expired - Fee Related CA2406837C (en) 2000-03-30 2000-10-05 Composite building components, and method of making same
CA002604613A Expired - Fee Related CA2604613C (en) 2000-03-30 2000-10-05 Composite building components, and method of making same
CA2660655A Expired - Fee Related CA2660655C (en) 2000-03-30 2000-10-05 Composite building components and method of making same

Family Applications Before (2)

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CA002406837A Expired - Fee Related CA2406837C (en) 2000-03-30 2000-10-05 Composite building components, and method of making same
CA002604613A Expired - Fee Related CA2604613C (en) 2000-03-30 2000-10-05 Composite building components, and method of making same

Country Status (12)

Country Link
EP (1) EP1272715B1 (en)
CN (1) CN1214165C (en)
AT (1) ATE440188T1 (en)
AU (1) AU2000277554A1 (en)
CA (3) CA2406837C (en)
DE (1) DE60042794D1 (en)
IL (2) IL152415A (en)
MX (1) MXPA02010688A (en)
RO (1) RO121389B1 (en)
RU (1) RU2002129010A (en)
TR (1) TR200202516T2 (en)
WO (1) WO2001075245A1 (en)

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6895723B2 (en) * 2002-08-29 2005-05-24 The Coe Manufacturing Company, Inc. Compressed wood waste structural I-beam
DE102010004029A1 (en) * 2010-01-04 2011-07-07 Martin Denesi Method for producing a particle-based element
DE102010004028A1 (en) * 2010-01-04 2011-07-07 Martin Denesi Method for producing a particle-based element
CA2928240C (en) * 2013-11-06 2019-02-26 Wood Innovations Ltd. Core layer having wood elements, in particular wood elements having a corrugated structure
CH709486A2 (en) * 2014-04-11 2015-10-15 Bionicalpha Ag Lightweight construction element, production method thereof, use thereof, and lightweight panels and insulation.
US10272619B2 (en) 2014-05-19 2019-04-30 The Boeing Company Manufacture of a resin infused one-piece composite truss structure
EP3224040B1 (en) * 2015-08-04 2022-05-18 Mock Beteiligungsgesellschaft mbH Web, sandwich plate, sandwich block and methods for producing same
CN106584968A (en) * 2016-12-28 2017-04-26 镇江博昊科技有限公司 Graphene composite material high in heat dissipation property
CN111055513B (en) * 2018-10-17 2021-09-14 哈尔滨工业大学 Preparation method of foldable fiber reinforced resin matrix composite truss and truss
CN111636411A (en) * 2020-05-19 2020-09-08 浙江云泊科技有限公司 WAC construction method for connecting underground continuous wall panels of storage box garage

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE835053C (en) * 1948-07-09 1952-03-27 Ji Te Ab Building panel and process for its manufacture
US5685124A (en) * 1994-04-21 1997-11-11 Jandl, Jr.; Adolf Wall, ceiling or roof elements with heat insulation properties on one side and sound insulation properties on the other

Also Published As

Publication number Publication date
TR200202516T2 (en) 2003-09-22
RO121389B1 (en) 2007-04-30
CA2604613C (en) 2010-01-12
CA2604613A1 (en) 2001-10-11
CA2660655C (en) 2011-12-20
EP1272715B1 (en) 2009-08-19
WO2001075245A1 (en) 2001-10-11
CA2406837C (en) 2009-06-23
DE60042794D1 (en) 2009-10-01
RU2002129010A (en) 2004-03-10
ATE440188T1 (en) 2009-09-15
CN1214165C (en) 2005-08-10
AU2000277554A1 (en) 2001-10-15
CN1454277A (en) 2003-11-05
CA2406837A1 (en) 2001-10-11
IL152415A0 (en) 2003-05-29
IL152415A (en) 2010-05-17
EP1272715A1 (en) 2003-01-08
MXPA02010688A (en) 2004-05-17
IL187180A0 (en) 2008-02-09
IL187180A (en) 2012-07-31

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