Reusable structure for use in construction

Abstract

A reusable modular structural member that may replace wooden structures used in concrete forming, transportation, marine, and construction applications. The reusable modular structural member includes a structural profile with first and second sides; a plurality of support beams extending from the first to the second side; at least two fasteners, one at a first end and another at a second end of each of the plurality of ribs; and a groove on a first edge and a tongue on a second edge that are configured to form a dovetail joint that can attach two reusable modular structural members of similar configuration. A reusable modular member can include the modular structural profile and interfacial layers covering the first and second sides. The reusable modular member may be made by extruding the structural profile and molding a plastic polymer to external portions of the structural profile to form the interfacial layers.

1 . A reusable structural member, the reusable structural member comprising:
 a structural profile having:
 a length, a width, and a thickness; 
 a first side and a second side opposite the first side, the first and second sides defining the width and the length; 
 a first edge and a second edge opposite the first edge, each of the first and second edges extending between the first and second sides and defining the thickness; 
 a plurality of support beams, each support beam extending between the first side and the second side; and 
 a fastener disposed at a first end of each of the plurality of support beams; and 
   an interfacial layer,   wherein the fasteners help secure the interfacial layer to the structural profile.   
     
     
         2 . The reusable structural member of  claim 1 , further comprising a groove disposed along the first edge and a tongue disposed along the second edge of the structural profile, the tongue configured to be disposed in a groove of a second reusable structural profile to join the reusable structural profile and the second reusable structural profile together, and the groove configured to receive a tongue of a third reusable structural profile to join the reusable structural profile and the third reusable structural profile together. 
     
     
         3 . The reusable structural member of  claim 1 , wherein the interfacial layer is configured to contact concrete while concrete is poured and sets. 
     
     
         4 . The reusable structural member of  claim 3 , wherein the interfacial layer is resistant to at least one of:
 alkaline pH conditions;   elevated temperatures;   water or other liquid absorption; and   abrasion by any of sand and aggregate.   
     
     
         5 . The reusable structural member of  claim 1 , wherein each of the fasteners is a male fastener that extends beyond the first side of the structural profile. 
     
     
         6 . The reusable structural member of  claim 5 , wherein the male fastener comprises a pair of protrusions surrounded by a portion of the interfacial layer. 
     
     
         7 . The reusable structural member of  claim 1 , wherein each of the fasteners is a female fastener that is formed in the first side of the structural profile and includes a recess into a corresponding support beam of the plurality of support beams. 
     
     
         8 . The reusable structural member of  claim 1 , wherein the structural profile is formed of metal. 
     
     
         9 . The reusable structural member of  claim 1 , further comprising: one or more open volumes, each of the one or more open volumes bounded by the first side or the second side, and at least one of the plurality of support beams; and filler disposed in the one or more open volumes. 
     
     
         10 . An extruded structural profile for casting concrete, comprising:
 a length, a width, and a thickness;   a first side and a second side opposite the first side, the first and second sides defining the width and the length;   a first edge and a second edge opposite the first edge, each of the first and second edges extending between the first and second sides and defining the thickness;   a plurality of support beams, each support beam extending between the first side and the second side;   a fastener disposed at a first end of each of the plurality of support beams, the fastener adapted to help secure an interfacial layer to the extruded structural profile; and   a female connector disposed along the first edge and a male connector disposed along the second edge, the male connector configured to be disposed in a female connector of a second extruded structural profile to join the extruded structural profile and the second extruded structural profile together, and the female connector configured to receive a male connector of a third extruded structural profile to join the extruded structural profile and the third extruded structural profile together.   
     
     
         11 . The extruded structural profile of  claim 10 , wherein the extruded structural profile is formed of a metal. 
     
     
         12 . The extruded structural profile of  claim 10 , wherein the female connector is a groove and the male connector is a tongue. 
     
     
         13 . The extruded structural profile of  claim 10 , wherein each of the fasteners is a male fastener that extends from a corresponding support beam of the plurality of support beams, the male fastener extending beyond the first side. 
     
     
         14 . The extruded structural profile of  claim 13 , wherein the male fastener includes first and second protrusions each extending beyond the first side. 
     
     
         15 . The extruded structural profile of  claim 14 , wherein each of the first and second protrusions extends outward from the first side at an angle between approximately 15 degrees and approximately 45 degrees. 
     
     
         16 . A method of manufacturing a reusable modular structural member for casting concrete, the method comprising:
 forming first and second structural profiles, each structural profile having:
 a length, a width, and a thickness; 
 a first side and a second side opposite the first side, the first and second sides defining the width and the length; 
 a first edge and a second edge opposite the first edge, each of the first and second edges extending between the first and second sides and defining the thickness; 
 a plurality of support beams, each support beam extending between the first side and the second side; and 
 a fastener disposed at a first end of each of the plurality of support beams; 
   connecting the first and second structural profiles by disposing a portion of the first structural profile in a portion of the second structural profile, thereby forming a connected structure; and   applying an interfacial layer on the connected structure.   
     
     
         17 . The method of  claim 16 , wherein forming the first and second structural profiles comprises extruding the first and second structural profiles using aluminum. 
     
     
         18 . The method of  claim 17 , wherein applying the interfacial layer of comprises molding a polymer material to external portions of the connected structure. 
     
     
         19 . The method of  claim 18 , further comprising flowing the polymer material into the fastener, the fastener comprising:
 a recess in a corresponding support beam of the plurality of support beams; or   one or more protrusions extending from a corresponding support beam of the plurality of support beams away from a middle portion of the connected structure.   
     
     
         20 . The method of  claim 16 , further comprising inserting a filler into one or more open volumes in the structural member, the one or more open volumes each bounded by the first side and the second side of the first or second structural profile and at least one of the plurality of support beams.