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A support beam and method for making a support beam, the support beam having a plurality of panels arranged side by side. The panels each have a core of insulative material and outer layers laminated to the core. The panels are adhered to one another and to top and bottom beam supports using bonding

A support beam and method for making a support beam, the support beam having a plurality of panels arranged side by side. The panels each have a core of insulative material and outer layers laminated to the core. The panels are adhered to one another and to top and bottom beam supports using bonding material.

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1. A support beam comprising: a plurality of panels arranged side by side sandwich relation, each panel comprising: a core having a center portion, a top, a bottom, a first side and a second side, anda first outer layer in contact with the first side,a second outer layer in contact with the second s

1. A support beam comprising: a plurality of panels arranged side by side sandwich relation, each panel comprising: a core having a center portion, a top, a bottom, a first side and a second side, anda first outer layer in contact with the first side,a second outer layer in contact with the second side,a top support; anda bottom support generally parallel to the top support and separated from the top support by the plurality of panels;a bonding material between a major surface of at least one of the top support and/or the bottom support and at least one of the plurality of panels, the bonding material securing the at least one of the top support and/or the bottom support to the at least one of the plurality of panels;wherein at least one of the top support and/or the bottom support includes at least two laminate layers to form a support, the first laminate layer comprising fibers orientated at 0 degrees, 90 degrees and +45 degrees and the second laminate layer comprising fibers oriented at 0 degrees, 90 degrees and −45 degrees, wherein the resulting combined laminate layers comprise fibers oriented at 0 degrees, 90 degrees, +45 degrees and −45 degrees. 2. The support beam of claim 1, wherein at least one of the top of the core and/or the bottom of the core is angled from the center portion to at least one of the first side and the second side. 3. The support beam of claim 1, wherein at least one of the top of the core and/or the bottom of the core is angled from the center portion to the first side and to the second side such that the length of the center portion is greater than the length of the first side and greater than the length of the second side. 4. The support beam of claim 1 further comprising bonding material between the panels. 5. The support beam of claim 1 wherein at least one of the first or second outer layer and core form a cavity and wherein the cavity is at least partially filled with bonding material. 6. The support beam of claim 5 wherein at least one of the first or second cavity is generally triangular. 7. The support beam of claim 1 wherein the length of the cavity is at least approximately seven times the thickness of the outer layer. 8. The support beam of claim 1 wherein at least one of the top support or the bottom support extends horizontally beyond the plurality of panels. 9. The support beam of claim 8, wherein the bonding material extends between a major surface of the first side of the first of the plurality of panels to the major surface of the at least one of the top support and/or the bottom support, and the bonding material extends between a major surface of the second side of the last of the plurality of panels to the major surface of the at least one of the top support and/or the bottom support. 10. The support beam of claim 9 wherein at least one of the bonding material joining the major surface of the first side of the first of the plurality of panels to the major surface of the at least one of the top support and/or the bottom support, and/or the bonding material joining the major surface of the second side of the last of the plurality of panels to the major surface of the at least one of the top support and/or the bottom support forms a round corner. 11. The support beam of claim 10 wherein the round corner has a radius that is at least about 7 times the thickness of the outer layer. 12. The support beam of claim 1 wherein at least one of the first or second outer layer and at least one of the top support and/or the bottom support are formed from the same materials. 13. The support beam of claim 1 wherein at least one of the top support or the bottom support is about 3 to 10 times as thick as at least on of the first or second outer layer. 14. A method for forming a support beam from a plurality of panels comprising: arranging a plurality of panels side by side, each panel having a top, a bottom, a first side and a second side, wherein the second side of a first panel is adjacent to the first side of a second panel;joining the plurality of panels with bonding material at each of the first side and second side of the plurality of panels, except for the first side of the first of the plurality of panels and the second side of the last of the plurality of panels;placing a top support adjacent to the top of the panels;applying bonding material to a major surface of the first side of the first of the plurality of panels and to a major surface of the top support to join the major surface of the first side of the first of the plurality of panels to the major surface of the top support;applying bonding material to a major surface of the second side of the last of the plurality of panels and to the major surface of the top support to join the major surface of the second side of the last of the plurality of panels to the major surface of the top support;placing a bottom support adjacent to the bottom of the panels;applying bonding material to the major surface of the first side of the first of the plurality of panels and to a major surface of the bottom support to join the major surface of the first side of the first of the plurality of panels to the major surface of the bottom support; andapplying bonding material to the major surface of the second side of the last of the plurality of panels and to the major surface of the bottom support to join the major surface of the second side of the last of the plurality of panels to the major surface of the bottom support;wherein at least one of the major surface of the top support and/or the major surface of the bottom support are formed by joining at least two laminate layers to form a support, the first laminate layer comprising fibers orientated at 0 degrees, 90 degrees and +45 degrees and the second laminate layer comprising fibers oriented at 0 degrees, 90 degrees and −45 degrees, wherein the resulting combined laminate layers comprise fibers oriented at 0 degrees, 90 degrees, +45 degrees and −45 degrees. 15. The method of claim 14 wherein applying bonding material to a major surface of the first side of the first of the plurality of panels to the at least one of the major surface of the top support and/or the major surface of the bottom support comprises forming the bonding material to a round corner. 16. The method of claim 14 wherein each of the plurality of panels comprises: a core having a center portion, a top, a bottom, a first side and a second side, wherein at least one of the top of the core or the bottom of the core is angled from the center portion to at least one of the first side and the second side such that the length of the center portion is greater than the length of at least one of the first side or the second side; andan outer layer in contact with the one of the first side or the second side having a length less than the length of the center portion of the core, the outer layer being positioned to extend beyond the length of the side with which the outer layer is in contact and terminate in substantially the same horizontal plane as the end of the center portion of the core such that the outer layer and core form a cavity; andwherein the method further comprises at least substantially filling the cavity in each of the plurality of panels prior to joining the top support and the plurality of panels. 17. The method of claim 16 further comprising for each of the plurality of panels removing a portion of the core near the outer layer to form the cavity. 18. The method of claim 14, wherein at least one of the step of applying bonding material to the major surface of the first side of the first of the plurality of panels and to a major surface of the bottom support and/or the step of applying bonding material to the major surface of the second side of the last of the plurality of panels and to the major surface of the bottom support comprises forming a round corner of bonding material between the bottom support and the major surface. 19. A method for forming a support beam from a plurality of panels comprising: arranging a plurality of panels side by side, each panel having a top, a bottom, a first side and a second side, wherein the second side of a first panel is adjacent to the first side of a second panel;joining the plurality of panels with bonding material at each of the first side and second side of the plurality of panels, except for the first side of the first of the plurality of panels and the second side of the last of the plurality of panels;joining at least two laminate layers to form a support, the first laminate layer comprising fibers orientated at 0 degrees, 90 degrees and +45 degrees and the second laminate layer comprising fibers oriented at 0 degrees, 90 degrees and −45 degrees, wherein the resulting combined laminate layers comprise fibers oriented at 0 degrees, 90 degrees, +45 degrees and −45 degrees;applying bonding material to a major surface of the first side of the first of the plurality of panels and to a major surface of the support to join the major surface of the first side of the first of the plurality of panels to the major surface of the support; andapplying bonding material to a major surface of the second side of the last of the plurality of panels and to the major surface of the support to join the major surface of the second side of the last of the plurality of panels to the major surface of the support.