IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
UP-0504394
(2006-08-15)
|
등록번호 |
US-7592059
(2009-10-20)
|
발명자
/ 주소 |
- Lane, Kevin K.
- Lane, legal representative, Dustin K.
- Carothers, Paul A.
- Lane, Ryan K.
- Faino, Ryan P.
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
4 인용 특허 :
13 |
초록
▼
A lightweight, reinforced composite structural element is disclosed, which includes a hollow housing, interior reinforcement, a filling of polyurethane foam, and a substantially uniform outer coating of a high-solid protective coating. The reinforced composite structural element can be used as a rai
A lightweight, reinforced composite structural element is disclosed, which includes a hollow housing, interior reinforcement, a filling of polyurethane foam, and a substantially uniform outer coating of a high-solid protective coating. The reinforced composite structural element can be used as a railroad tie and for other construction uses. The structural element is formed with a housing having end caps or ends sealed by flaps that are connected with and bendable from the housing material to create a sealed container with openings for injection of the foam into cavities of the housing formed by the interior reinforcement.
대표청구항
▼
What is claimed: 1. A composite structural element comprising: a hollow flame made from a rigid material, said hollow flame having an interior, and an exterior, wherein the hollow flame is an elongated rectangular box, and wherein the hollow flame further comprises: a single U-shaped section compri
What is claimed: 1. A composite structural element comprising: a hollow flame made from a rigid material, said hollow flame having an interior, and an exterior, wherein the hollow flame is an elongated rectangular box, and wherein the hollow flame further comprises: a single U-shaped section comprising: an open side; a closed bottom surface; a first arm; and a second arm substantially parallel to the first arm, the first arm and second arm connected with and perpendicular to the closed bottom surface; a top section positioned over the open side substantially parallel to the closed bottom surface and joined with the first arm and the second arm; a first flap which is an extended portion of a first end of one of the first arm, the second arm, and the closed bottom surface, and bendably correspondingly connected with the first end of one of the first arm, the second arm, and the closed bottom surface, the first flap bending into position to cover and seal the first end of the hollow frame; a second flap which is an extended portion of a second end of one of the first arm, the second arm, and the closed bottom surface, and bendably correspondingly connected with the second end of one of the first arm, the second arm, and the closed bottom surface, the second flap bending into position to cover and seal the second end of the hollow frame; a polyurethane foam that reacts and becomes rigid in the interior such that the polyurethane foam completely fills open portions of the interior; and a substantially uniform high-solid protective coating provided over the exterior of the hollow frame. 2. The composite structural element as in claim 1 wherein the composite structural element is a railroad tie. 3. The composite railroad tie as in claim 1, wherein the hollow frame is an elongated rectangular box, and the hollow frame further comprises two U-shaped sections joined together. 4. The composite structural element as in claim 1 wherein the hollow frame is made of a material selected from the group consisting of steel, low-gauge steel, cardboard, impregnated paper, extruded metal alloys, welded metal alloys, glued metal alloys, formed metal alloys, polypropylene plastic, resin, fiberglass-reinforced polyesters, polyester fabrics saturated with epoxy, plastics or liquid rubber, and thin structural plywood. 5. The composite structural element as claimed in claim 1 wherein the composite structural member further comprises: at least one reinforcing member comprising a rigid material, said at least one reinforcing member placed in the interior adjacent the polyurethane foam to provide support to the hollow frame. 6. The composite structural element as in claim 5 wherein the at least one reinforcing member comprises at least one plank of wood. 7. The composite structural element as in claim 5 wherein the at least one reinforcing member further comprises at least one I-beam having a length substantially shorter than a length of the hollow frame. 8. The composite structural element as in claim 5 wherein the at least one reinforcing member further comprises at least one hollow box. 9. The composite structural element as in claim 5 wherein the at least one reinforcing member further comprises a first C-section and a second C-section, wherein a first closed end of the first C-section abuts a second closed end of the second C-section, and the first closed end and the second closed end are joined together. 10. The composite structural element of claim 5, further comprising: at least one aperture from the exterior through to the interior, said aperture adapted to accommodate an injection nozzle for providing the polyurethane foam to the interior, said aperture having a size that accommodates the injection nozzle. 11. The composite structural element of claim 5, wherein the high solid protective coating is a UV-resistant polyurea. 12. The composite structural element of claim 5, wherein the high solid protective coating is a UV-stable aliphatic polyurethane coating, wherein the UV-stable aliphatic polyurethane coating. 13. The composite structural element of claim 12 wherein the UV-stable aliphatic polyurethane coating is self-extinguishing of fire, and is non-shrinking. 14. The composite railroad tie of claim 5, wherein the at least one reinforcing member is positioned to securely attach at least one railroad spike. 15. The composite structural element as in claim 1 wherein the first flap bends into position to form a first end cap, and wherein the second flap bends into position to form a second end cap, the composite structural element further comprising: at least one aperture in at least one of the first end cap and the second end cap, the at least one aperture adapted to accommodate an injection nozzle for providing the polyurethane foam to the interior. 16. A composite structural element comprising: a hollow frame made from a rigid material, said hollow frame having an interior, and an exterior, said hollow frame further comprising: a single U-shaped section further comprising: an open side; a closed bottom surface; a first arm; and a second arm substantially parallel to the first arm, the first arm and second arm connected with and perpendicular to the closed bottom surface; and a top section positioned over the open side substantially parallel to the closed bottom surface and joined with the first arm and the second arm; a first flap which is an extended portion of a first end of one of the first arm, the second arm, and the closed bottom surface, and bendably correspondingly connected with the first end of one of the first arm, the second arm, and the closed bottom surface, the first flap bending into position to cover and seal the first end of the hollow frame; a second flap which is an extended portion of a second end of one of the first arm, the second arm, and the closed bottom surface, and bendably correspondingly connected with the second end of one of the first arm, the second arm, and the closed bottom surface, the second flap bending into position to cover and seal the second end of the hollow frame; at least one insertion block in the interior, the insertion block adapted to comprise a support of the hollow frame in at least one part where pressure is to be applied; a plank of wood positioned along the interior of the first arm and the second arm; a plurality of apertures through the hollow frame and the planks of wood to allow injection of a polyurethane foam; the polyurethane foam that reacts and becomes rigid in the interior and completely fills the interior of the hollow frame apart from the at least one insertion block; and a substantially uniform high-solid protective coating provided over the exterior of the hollow frame.
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