REINFORCED STRUCTURAL MEMBER AND FRAME STRUCTURES

• US 20090094929A1
• Filed: 10/16/2008
• Published: 04/16/2009
• Est. Priority Date: 08/02/2004
• Status: Active Grant

• Current Assignee: TAC Technologies LLC
• Original Assignee: TAC Technologies LLC
• Inventors: Carlson, Barry L., Underhill, Jason
• Granted Patent: US 8,266,856 B2
• Time in Patent Office: Days
• US Class Current: 52/656.2
• CPC Class Codes: B29C 37/0082 Mechanical anchoring B29C66/303 takes precedence
• CPC Class Codes: B29C 44/18 Filling preformed cavities B29C44/1204 takes precedence
• CPC Class Codes: B29C 48/001 Combinations of extrusion moulding with other shaping operations
• CPC Class Codes: B29C 48/0022 combined with cutting
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/11 comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/151 Coating hollow articles
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B32B 3/263 characterised by a layer having non-uniform thickness
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: E04F 15/10 of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: F24S 2080/015 Plastics
• CPC Class Codes: F24S 25/00 Arrangement of stationary mountings or supports for solar heat collector modules
• CPC Class Codes: Y10T 29/49616 Structural member making
• CPC Class Codes: Y10T 29/49623 Static structure, e.g., a building component
• CPC Class Codes: Y10T 29/49627 Frame component
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 428/24331 including nonapertured component
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24521 : with component conforming to contour of nonplanar surface
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet

Abstract

Disclosed are frame members and mullions for a window frame that comprise a reinforcing member that is surrounded by an outer plastic layer. The outer plastic layer is held securely to the reinforcing member as a result of a waist banding effect that comprises an inward force created by the outer plastic layer as it cools and contracts around the reinforcing member. In addition, lobes are formed in the reinforcing member that assist in holding the outer plastic layer to the reinforcing member. Window inserts can be removed and replaced using adapters and removable brackets. Frame members and mullions can be built sufficiently strong to provide structural support. The frame can also be used to hold photovoltaic cells and protective coverings for photovoltaic cells. Structural members are also disclosed that have reinforcing members with apertures, debossing, scarification and/or indentations that secure the thermoplastic layer to the reinforcing member.

Claims

1. A frame structure comprising:

a reinforcing member having an outer surface and at least a portion having a substantially hollow interior, a plurality of lobes formed in said reinforcing member that have an interior lobe that is larger than a waist opening;

a first plastic layer that is extruded into said lobes and extends into said waist opening;

an exterior plastic layer that is extruded over substantially all of said outer surface of said reinforcing member while said first plastic layer is sufficiently hot to knit said exterior plastic layer to said first plastic layer to form a substantially unitary plastic coating structure comprising said first plastic layer and said exterior plastic layer that is held securely to said reinforcing member by said first plastic layer that is disposed in said lobes, said exterior plastic layer creating an inward force on said reinforcing member as said exterior plastic layer cools and contracts to further hold said exterior plastic layer securely to said reinforcing member;

a recess formed in said reinforcing member that is covered by said substantially unitary plastic coating structure that secures an insert to said frame structure.

2. The frame structure of claim 1 wherein said frame structure comprises a non-structural frame member.

3. The frame structure of claim 2 wherein said frame structure comprises a mullion.

4. The frame structure of claim 1 wherein said insert comprises a frame for a protective layer for a photodetector.

5. The frame structure of claim 2 wherein said frame structure comprises a window frame.

7. The frame structure of claim 5 wherein said frame structure comprises a non-structural frame member.

9. The frame structure of claim 7 wherein said insert comprises a window.

10. The frame structure of claim 7 wherein said insert comprises a photovoltaic detector.

11. The frame structure of claim 7 wherein said insert comprises a protective layer for a photovoltaic detector.

6. A frame structure comprising:

a reinforcing member having an outer surface and at least a portion that has a substantially hollow interior, a plurality of lobes formed in said reinforcing member that have an interior lobe dimension that is larger than a lobe waist opening;

a first plastic layer that is extruded into said lobes and extends into said lobe waist opening;

an exterior plastic layer that is extruded over substantially all of said outer surface of said metal reinforcing member while said first plastic layer is sufficiently hot to knit said exterior plastic layer to said first plastic layer to form a substantially unitary plastic coating structure comprising said first plastic layer and said exterior plastic layer that is held securely to said reinforcing member by said first plastic layer that is disposed in said lobes, said exterior plastic layer creating an inward force on said reinforcing member as said exterior plastic layer cools and contracts to further hold said exterior plastic layer securely to said reinforcing member;

a recess formed in said reinforcing member that is covered by said substantially unitary plastic coating structure that secures an insert to said frame member;

a removable bracket that is attached to said support structure that supports said insert and allows said insert to be removed from said frame structure whenever said removable bracket is removed from said reinforcing member.

8. The frame structure of claim 6 wherein said frame structure comprises a mullion.

12. A method of making a frame structure comprising:

providing a reinforcing member having an outer surface and at least a portion having a substantially hollow interior;

forming a plurality of lobes in said reinforcing member having an interior lobe size that is larger than a lobe waist opening;

extruding a first plastic layer into said plurality of lobes until said plastic extends into said lobe waist opening;

extruding an exterior plastic layer over substantially all of said outer surface of said reinforcing member while said first plastic layer is sufficiently hot to knit to said exterior plastic layer to form a substantially unitary plastic coating structure comprising said first plastic layer and said exterior plastic layer that is securely held to said reinforcing member by said first plastic layer that is disposed in said lobes, said exterior plastic layer creating an inward force on said reinforcing member as said exterior plastic layer cools and contracts to further hold said exterior plastic layer securely to said reinforcing member.

13. The method of claim 12 further comprising:

holding an insert in a recess formed in said metal reinforcing member that is covered by said substantially unitary plastic coating structure to secure said insert to said frame structure.

14. The method of claim 13 wherein said insert comprises a window insert.

15. The method of claim 13 wherein said insert comprises a photovoltaic detector.

16. A method of forming a structural member comprising:

providing a reinforcing member that has a predetermined shape, said reinforcing member providing structural rigidity to said structural member;

working at least a portion of said reinforcing member to form worked portions of said reinforced member;

passing said reinforced member through a crosshead die extruder that utilizes crosshead dies;

extruding a thermoplastic using said crosshead die extruder over an outer surface of said reinforcing member at a temperature within a predetermined temperature range so that said thermoplastic adheres to said worked portions of said reinforcing member to form said structural member.

17. The method of claim 16 further comprising:

reducing said temperature of said thermoplastic with water after said structural member exits said crosshead die extruder;

allowing said thermoplastic to further cool in air for more than one day.

18. The method of claim 16 wherein said process of working at least a portion of said reinforcing member comprises forming apertures in said reinforcing member.

19. The method of claim 16 wherein said process of extruding said thermoplastic causes said thermoplastic to form lobes in said apertures that secure said thermoplastic to said reinforcing member.

20. The method of claim 16 wherein said process of working at least a portion of said reinforcing member comprises forming divots in said structural member.

21. The method of claim 16 wherein said process of working at least a portion of said reinforcing member comprises forming scarification on at least one surface of said reinforcing member.

22. The method of claim 16 wherein said process of working at least a portion of said reinforcing member comprises forming indentations in said reinforcing member.

23. The method of claim 16 wherein said process of providing a reinforcing member comprises:

providing a roll sheet of metal alloy material;

progressively bending said metal allow material that is unrolled from said roll sheet to form said reinforcing member having said predetermined shape.

24. The method of claim 16 wherein said process of providing a reinforcing member comprises:

extruding a reinforcing member to form said predetermined shape.

25. A structural member comprising:

a reinforcing member that forms a structural support for said structural member, said reinforcing member having a predetermined shape and worked portions;

a thermoplastic layer that is extruded over at least a portion of said reinforcing member using a crosshead die extruder at a temperature in a predetermined temperature range to cause a thermoplastic material, that has a viscosity that is sufficiently low, to engage and adhere to said worked portions of said reinforcing member.

26. The structural member of claim 25 wherein said worked portions comprise:

apertures formed said reinforcing member.

27. The structural member of claim 25 wherein said worked portions comprise:

scarification formed on a surface of said reinforcing member.

28. The structural member of claim 25 wherein said worked portions comprise:

divots formed on a surface of said reinforcing member using a debossing device.

29. The structural member of claim 28 wherein said divots have a spatial separation and size that distributes stress over said thermoplastic layer.

30. The structural member of claim 25 further comprising:

talc disposed in said thermoplastic layer that increases the modulus of elasticity of said thermoplastic layer.