Composite load bearing structure

Abstract

A composite load bearing member is provided comprising an elongated inner structural member and a thick polymeric composite outer member. An apparatus for producing the composite load bearing member is provided including devices for suspending the inner structural member within a mold cavity prior to and during injection of the polymeric composite outer member. A method of using the apparatus to produce the composite load bearing member is provided.

1 . A composite load bearing member, comprising:
 an inner structural member, said inner structural member having a proximal end and a distal end, said inner structural member having a structural cross-section longitudinally elongated along a side surface from said proximal end to said distal end; and   an outer composite member, said outer composite member completely encapsulating said inner structural member, said outer composite member comprising between 20% and 95% of said load bearing member by volume, said outer composite member being comprised of between 35% and 100% polymeric material.   
   
   
       2 . The composite load bearing member of  claim 1  further comprising a plurality of suspension members, said suspension members being located radially about said inner member and extending from the surface of said inner structural member to the outer surface of said composite load bearing member. 
   
   
       3 . The composite load bearing member of  claim 2  further comprising a block member, said block member being located at said distal end of said inner structural member. 
   
   
       4 . The composite load bearing member of  claim 3  wherein said inner structural member is comprised of wood. 
   
   
       5 . The composite load bearing member of  claim 4  wherein the surface of said composite load bearing member is deformed to fill in any gaps between said suspension members and said outer composite member. 
   
   
       6 . The composite load bearing member of  claim 5  wherein said outer composite member is comprised of material selected from the group consisting of post-consumer polymers, post-industrial polymers, and non-polymeric additives. 
   
   
       7 . The composite load bearing member of  claim 5  wherein said outer composite member is comprised of material selected from the group consisting of recycled thermoplastic materials, waste thermoset materials, and non-polymeric additives. 
   
   
       8 . The composite load bearing member of  claim 7  wherein said outer composite member comprises between 45% and 70% of said composite load bearing member by volume. 
   
   
       9 . A composite load bearing member, comprising:
 an inner structural member, said inner structural member having a proximal end and a distal end, said inner structural member being comprised of wood, said inner structural extending longitudinally from said proximal end to said distal end;   an outer composite member, said outer composite member completely encapsulating said inner structural member, said outer composite member comprising between 20% and 95% of said load bearing member by volume, said outer composite member being comprised of between 35% and 100% polymeric material;   a suspension member, said suspension member being located about said inner structural member and extending radially from the surface of said inner structural member to the outer surface of said composite load bearing member; and   a block member, said block member being located at said distal end of said inner structural member.   
   
   
       10 . The composite load bearing member of  claim 9  wherein the cross section of inner structural member is of a general shape selected from the group consisting of rectangular and circular. 
   
   
       11 . The composite load bearing member of  claim 10  wherein said composite load bearing member has a proximal end and a distal end, said composite load bearing member being of general cross-sectional shape selected from the group consisting of rectangular and circular, said cross-sectional shape extending longitudinally from said proximal end to said distal end of said composite load bearing member. 
   
   
       12 . The composite load bearing member of  claim 11  wherein the thickness of said outer composite member is between 0.5 inches and 2.5 inches. 
   
   
       13 . The composite load bearing member of  claim 12  wherein the surface of said composite load bearing member is deformed to fill in any gaps between said suspension member and said outer composite member. 
   
   
       14 . The composite load bearing member of  claim 13  wherein said outer composite member is comprised of material selected from the group consisting of post-consumer polymers, post-industrial polymers, and non-polymeric additives. 
   
   
       15 . The composite load bearing member of  claim 13  wherein said outer composite member is comprised of material selected from the group consisting of recycled thermoplastic materials, waste thermoset materials, and non-polymeric additives. 
   
   
       16 . An apparatus for manufacturing a composite load bearing member, comprising:
 a mold member having a longitudinal cavity with a proximal end and a distal end, wherein an elongate inner structural member is located internally to said mold member via a plurality of suspension members;   a block member, said block member juxtaposed said proximal end of said elongate inner structure; and   a reversibly actuating gate member attached to said proximal end of said longitudinal cavity through which a polymeric material may be forced to completely encapsulate said elongate inner structural member.   
   
   
       17 . The apparatus of  claim 16  wherein said elongate inner structural member is located a specified distance from said distal end of said longitudinal cavity via said block member. 
   
   
       18 . The apparatus of  claim 17  wherein said plurality of suspension members is comprised of a polymeric material, said plurality of suspension members being attached to said inner structural member. 
   
   
       19 . The apparatus of  claim 17  wherein said plurality of suspension members is a plurality of retractable pin members extending from said cavity of said mold member wherein said plurality of retractable pin members may be retracted. 
   
   
       20 . The apparatus of  claim 17  wherein said plurality of suspension members are reversibly attached to said inner structural member and removable after solidification of said polymeric material. 
   
   
       21 . A method of producing a composite load bearing member, comprising:
 selecting an elongate inner structural member having a proximal and distal end;   attaching suspension members to said elongate inner structural member, said suspension members being comprised of a material capable of bonding with a polymeric mixture;   attaching a block member to the distal end of said elongate inner structural member, said block member being comprised of a material capable of bonding with a polymeric mixture;   placing said elongate inner structural member into a mold member having a cavity with a proximal and distal end, said elongate structural member being internally located within said cavity via said suspension members and spaced a specified distance from said distal end of said cavity via said block member;   preparing said polymeric mixture;   forcing said polymeric mixture through a closable gate member attached to said proximal end of said cavity;   closing said gate member;   allowing said polymeric mixture to solidify;   ejecting said composite load bearing member from said cavity of said mold member; and   hot stamping a textured pattern onto at least a portion of the surface of said composite load member.