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Patent 3081579 Summary

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(12) Patent Application: (11) CA 3081579
(54) English Title: STRUCTURAL REINFORCED COMPOSITE BEAM
(54) French Title: POUTRE STRUCTURALE COMPOSITE RENFORCEE
Status: Examination Requested
Bibliographic Data
(51) International Patent Classification (IPC):
  • E04C 3/29 (2006.01)
(72) Inventors :
  • BROWN, CLAUDE, JR. (United States of America)
  • CRANE, DAVID C. (United States of America)
  • COMBS, ROBERT E. (United States of America)
(73) Owners :
  • PLASTIC TIES TECHNOLOGIES LLC (United States of America)
(71) Applicants :
  • AXION STRUCTURAL INNOVATIONS LLC (United States of America)
(74) Agent: GOWLING WLG (CANADA) LLP
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 2018-11-03
(87) Open to Public Inspection: 2019-05-09
Examination requested: 2021-11-04
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US2018/059107
(87) International Publication Number: WO2019/090187
(85) National Entry: 2020-05-01

(30) Application Priority Data:
Application No. Country/Territory Date
62/581,261 United States of America 2017-11-03
16/179,178 United States of America 2018-11-02

Abstracts

English Abstract

A beam assembly includes a plastic composite beam and a flitch plate, where the flitch plate is secured to the plastic composite beam to improve the strength and rigidity of the beam. The assembly may include a plurality of rods extending through holes defined in the flitch plate and the beam to compress the flitch plate and the beam and to create a frictional engagement between the flitch plate and the beam. The flitch plate may have a height that is less than the height of the beam, such that upper and lower surfaces of the flitch plate are recessed from the upper and lower surfaces of the beam. The assembly may include two beams with a flitch plate disposed laterally between the beams. The flitch plate may include projections or protrusions that engage the beams to secure the flitch plate to the beams.


French Abstract

L'invention concerne un ensemble poutre comprenant une poutre composite en plastique et une plaque d'éclisse, la plaque d'éclisse étant fixée à la poutre composite en plastique pour améliorer la résistance et la rigidité de la poutre. L'ensemble peut comprendre une pluralité de tiges s'étendant à travers des trous définis dans la plaque d'éclisse et la poutre pour comprimer la plaque d'éclisse et la poutre et pour créer une interaction de frottement entre la plaque d'éclisse et la poutre. La plaque d'éclisse peut présenter une hauteur plus petite que la hauteur de la poutre, de telle façon que des surfaces supérieure et inférieure de la plaque d'éclisse soient en retrait par rapport aux surfaces supérieure et inférieure de la poutre. L'ensemble peut comprendre deux poutres avec une plaque d'éclisse disposée latéralement entre les poutres. La plaque d'éclisse peut comprendre des saillies ou protubérances qui interagissent avec les poutres pour fixer la plaque d'éclisse aux poutres.

Claims

Note: Claims are shown in the official language in which they were submitted.


CLAIMS
What is claimed is:
1. A composite beam assembly comprising:
a first plastic composite beam having a longitudinal length and top and bottom

surface defining a height therebetween and first and second side surfaces
defining a
width therebetween; and
a flitch plate having a longitudinal length and having top and bottom surfaces

defining a height therebetween and first and second side surfaces defining a
width
therebetween;
wherein the width of the beam is greater than the width of the flitch plate;
wherein the flitch plate is secured to the beam to provide additional
stiffness to
the beam.
2. The assembly of claim 1, wherein the flitch plate is metal or fiber-
reinforced
resin.
3. The assembly of claim 1, further comprising a second composite plastic
beam
secured to the flitch plate.
4. The assembly of claim 3, wherein the flitch plate is disposed laterally
between
the first and second composite beams.
5. The assembly of claim 1, wherein the height of the flitch plate is less
than the
height of the beam.
16

6. The assembly of claim 1, wherein the top of the flitch plate is recessed
relative
to the top surface of the beam, and the bottom of the flitch plate is recessed
relative to
the bottom of the beam.
7. The assembly of claim 1, further comprising a rod extending laterally
through
holes formed in the flitch plate and beam, wherein the rod compresses the
flitch plate
and beam against each other in a lateral direction.
8. The assembly of claim 1, wherein the flitch plate includes a grip-
enhancing
feature to increase friction between the flitch plate and the beam.
9. The assembly of claim 1, wherein the flitch plate includes a plurality
of
projections that pierce the composite beam.
10. The assembly of claim 1, wherein the flitch plate includes a plurality
of posts
extending from a surface thereof, wherein the posts are received in
corresponding
structure of the composite beam when assembled.
11. The assembly of claim 1, wherein the flitch plate includes a plurality
of ribs
extending from a surface thereof, wherein the ribs are received in
corresponding
structure of the composite beam when assembled.
12. The assembly of claim 1, wherein the flitch plate has an L-shaped cross-
section
or a T-shaped cross-section having a long leg and at least one short leg, and
the long
leg and the at least one short leg each contact the composite beam.
17

13. The assembly of claim 1, wherein the assembly the first flitch plate
and the first
composite beam are the only flitch plate and beam of the assembly.
14. The assembly of claim 1, further comprising a second flitch plate,
where the
composite beam is disposed laterally between the first and second flitch
plates.
15. The assembly of claim 14, wherein the first and second flitch plates
are recessed
inwardly from a laterally outermost surface of the beam.
16. The assembly of claim 1, wherein the flitch plate and the composite
beam are
clamped together with a clamp.
17. The assembly of claim 1, wherein the flitch plate and the composite
beam are
bound together with a band surrounding the flitch plate and the beam.
18. The assembly of claim 7, wherein the hole in the flitch plate is in the
form of a
slot extending in the longitudinal direction to allow relative longitudinal
movement
between the flitch plate and the beam in response to longitudinal expansion
and
contraction of the beam.
19. The assembly of claim 1, wherein the flitch plate has a C-shaped cross-
section
having a long leg and two short legs, and the short legs are recessed from an
outermost
surface of the beam.
18

20. The assembly of claim 1, wherein the flitch plate has an I-shaped cross-
section
with a long leg and four short legs, and the short legs are recessed from an
outermost
surface of the beam.
21. A beam assembly comprising:
at least one beam member fabricated of a composite plastics material
comprising a blend of polypropylene and polyethylene (PP:PE) , but
predominately
polyethylene, with 5-50% glass fiber reinforcement; and
at least one flitch plate fabricated of steel or glass fiber reinforced resin
material
haying a higher modulus of elasticity than that of said composite plastics
beam member
material, said beam member and said flitch plate being secured tightly
together in side-
by-side contacting relation and the resultant assembly haying a higher load-
bearing
strength and stiffness than either the beam member or flitch alone or in
combination
but not tightly secured to one another.
19

Description

Note: Descriptions are shown in the official language in which they were submitted.


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STRUCTURAL REINFORCED COMPOSITE BEAM
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of United States Provisional Patent

Application Number 62/581,261, filed November 3, 2017, and United States
Utility Patent
Application Number 16/179,178, filed November 2, 2018, the contents of which
are hereby
incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Technical Field
[0002] This invention relates generally to beam assemblies for use in
structural support
applications.
2. Related Art
[0003] Structural beams are typically made of steel or wood. Each has its
advantages
and disadvantages. Composite plastics material has been used for railroad beam
applications
but likewise has its limitations.
[0004] While wood is readily available and relatively inexpensive, it has
attributes
which make it less than an ideal material for use in exterior beam
applications. Woods beams
are known to have inconsistent performance over their life span even when used
under the
best conditions. The wood in a new beam will continue to season and shrink
over time. The
environment also has a tremendous impact on the performance and integrity of
the wood.
When exposed to wet conditions, the wood absorbs water and becomes water-
logged and
heavy. Soaked wood can lose as much as 2/3 of its beam strength which has a
direct impact
on the load-carrying capacity of the beam. Wood is further prone to fungus and
insect attack,
rotting and deterioration, especially in extremely harsh, wet applications,
greatly limiting the
useful service life and safe utilization of wooden beams. Even extreme dry
conditions present
a problem of embrittlement and dry rot for wood. Wood can be quickly eroded
under the load
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and abuse of heavy equipment, especially tracked vehicles, the caterpillar
tracks of which are
prone to digging into wood beams and gouging and shredding the wood fiber if
exposed. Such
wear and tear on exposed wood beams is greatly magnified in wet operating
conditions and
serves to thin the beams and create crack-initiation risers at the surface
which further
compromise the integrity load-carrying capacity of wood beams under heavy
load.
[0005] Wood used in beam applications is sometimes treated with chemicals to
help
preserve the wood in wet conditions. Wood will also soak up any oil and other
chemicals that
it may come into contact with at a construction site. Some of these chemicals
are toxic to the
environment and can be leached back into the soil.
SUMMARY OF THE INVENTION
[0006] A composite beam assembly constructed according to one preferred
embodiment of the invention comprises at least one beam member fabricated of
plastics-
based composite material and at least one flitch plate which may be fabricated
of steel or
other similarly performing material such as glass fiber reinforced resin. The
at least one beam
member and flitch plate are secured tightly together and the combination
enhances the overall
structural rigidity and beam strength of the beam assembly beyond what the at
least one
composite beam and flitch plate alone or in combination would provide in a
disassembled
state.
[0007] The structural reinforced composite beam assembly constructed according
to a
preferred embodiment of the invention has the advantage of being lighter,
stronger, longer
lasting and consistent in performance during its extended lifecycle than
timber beams for
outdoor applications in particular and its plastics-based beam members do not
shrink over
time. The beam assembly does not lose strength in prolonged wet conditions,
nor does it
absorb water, rot or otherwise deteriorate during use or exposure. The beam
assembly can be
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pre-engineered to the strength and load requirements of a particular job and
will maintain its
properties throughout its service life, unlike a wood beam.
BRIEF DESCRIPTION OF THE FIGURES
[0008] These and other features and advantages of the invention will be better

understood when considered in connection with embodiments of the invention
illustrated in
the following figures and described in greater detail below:
[0009] Figure 1 is a perspective view of an embodiment of a structural
reinforced
composite beam assembly including two beam members and a flitch plate;
[0010] Figure 2 is a cross-sectional view of the beam assembly;
[0011] Figure 3 is a fragmented exploded view of one of the beam members and
the
flitch plate, illustrating holes extending therethrough for receiving a rod;
[0012] Figure 4 is a cross-sectional view of another beam assembly held
together with
a clamp;
[0013] Figure 5 is a cross-sectional view of another beam assembly held
together with
a band;
[0014] Figure 6 is a fragmentary view of the flitch plate having a textured
surface;
[0015] Figure 7 is a cross-sectional view of another beam assembly having a
flitch plate
with projections that pierce the material of the beam members;
[0016] Figure 8 is a cross-sectional view of another beam assembly having a
flitch plate
with ribs and/or posts that are received in the beam members;
[0017] Figures 9A-9D are cross-sectional views of another beam assembly and
alternative flitch plates, where the flitch plates have a convex and/or
concave outer surface;
[0018] Figure 10 is a cross-sectional view of another beam assembly with an
alternative
flitch plate;
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[0019] Figure 11 is a cross-sectional view of another beam assembly with an
alternative
flitch plate;
[0020] Figure 12 is a cross-sectional view of another beam assembly with an
alternative
flitch plate;
[0021] Figure 13 is a cross-sectional view of another beam assembly with an
alternative
flitch plate;
[0022] Figure 14 is a cross-sectional view of another beam assembly with two
flitch
plates;
[0023] Figure 15 is a cross-sectional view of another beam assembly with two
flitch
plates;
[0024] Figure 16 is a cross-sectional view of another beam assembly with two
flitch
plates;
[0025] Figure 17 is a cross-sectional view of another beam assembly with an
alternative
flitch plate;
[0026] Figure 18 is a cross-sectional view of another beam assembly with two
flitch
plates;
[0027] Figure 19 is a cross-sectional view of another beam assembly with two
flitch
plates on opposite lateral sides of the beam member;
[0028] Figure 20 is a cross-sectional view of another beam assembly with two
beam
members and three flitch plates, with two of the flitch plates on opposite
lateral sides of the
beam assembly and one of the flitch plates between the two beam members;
[0029] Figure 21 is a cross-sectional view of another beam assembly with two
beam
members and two flitch plates, with one lateral side of the beam assembly free
from a flitch
plate; and
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[0030] Figure 22 is a cross-sectional view of another beam assembly with one
beam
members and one flitch plate, with the flitch plate being on one side of the
beam member.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] A structural reinforced composite beam assembly constructed according
to an
embodiment of the invention is generally shown in perspective view in Figure 1
and indicated
by reference numeral 10.
[0032] The assembly 10 has a top surface 12, a bottom surface 14,
longitudinally
opposite ends 16 and laterally opposite sides 18. The beam assembly 10 has an
overall length
dimension Lbeam extending between the two ends 16, an overall width dimension
Wbeam
extending between the two sides 18, and an overall thickness Tbeam dimension
extending
between the top 12 and bottom 14 surfaces.
[0033] The assembly 10 illustrated in Figure 1 includes at least one and, as
illustrated,
a pair of individual beam members 20 and at least one flitch plate 22.
[0034] The beam members 20 each have a thickness dimension Tb, a width
dimension
Wb, and a length dimension Lb.
[0035] The beam members are of a plastics (polymer) material, preferably a
structural
thermoplastic composite polymer. One such material suitable for the beams 20
is an HDPE-
based proprietary structural composite plastic beam material available from
Axion Structural
Innovations, of Zanesville, Ohio. Such plastics material comprises a blend of
polypropylene
and polyethylene (PP:PE) , but predominately polyethylene with 5-50% glass
fiber
reinforcement, and more preferably 5-25% glass fiber reinforcement. Other HDPE-
based
plastics materials may also be suitable depending upon the structural load
requirements of a
particular application, as well as plastics materials in general provided they
are able to meet
the load and strength and environmental requirements that a particular
application may call
for. It is thus to be understood that the invention contemplates the usage of
a variety of plastics

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materials and plastic based composite material systems as the beam 20
material, particularly
when coupled with the structural, load-enhancing flitch plate 22 to be
explained in more detail
below. The idea is that the composite plastics beams 20 and metallic flitch
plate(s) 22 work
in synergy to collectively provide a lightweight, strong and water/chemical
resistant beam
assembly suitably reinforced by the flitch plate(s) 22 to yield the strength
and rigidity required
of a particular job application for which the assembly 10 is to be used. The
flitch plate(s) 22
thus open up the possibilities for the types of candidate plastics materials
beyond what may
be otherwise suitable for beam application on their own without the flitch
plates. For example,
plastics materials that on their own may not possess the strength or rigidity
required for use
on their own as beams 20 may well become suitable when paired with one or more
flitch
plates 22, such that the overall structure is able to meet the requirements of
an application.
[0036] The dimensions of the individual beams 20 may vary depending upon the
requirements of a particular application and the material used for the beams.
For example, the
beam 20 may have a thickness Tb x width Wb x length Lb of, respectively, 9
inches x 7 inches
x 24 feet. As will be explained below, the beam 20 may be turned on edge such
that the
TxWxL dimensions are now 7" x 9" x 20' as in the embodiment of Figure 4.
[0037] The flitch plate(s) 22 is preferably fabricated of metal and preferably
steel. The
grade of steel may be ASTM A36. The flitch plate(s) 22 each have a thickness
dimension
Tflitch, a width dimension Wflitch, and a length dimension Lflitch. For the 24
foot beam 20
above with a 9" thickness, the T, W and L dimensions of the flitch plates 22
are, for example,
8.5 inches x 0.5 inches x 288 inches. For the 7" beam thickness embodiment of
Figure 4, the
thickness of the flitch plates 22 is reduced to 6.5", the width reduced to
0.25 inches, and the
length reduced to 238 inches. Other materials could be used in the
construction of the flitch
plates, such as glass fiber reinforced resin. The selected material for the
flitch plates will be
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different than the material of the beams. The thickness of the flitch plate(s)
may vary
depending upon the application.
[0038] As illustrated in Figures 1-2, the beams 20 and flitch plate(s) 22
extend in the
lengthwise direction of the assembly 10. The beams 20 are arranged adjacent to
one another.
In between the beams 20 is provided at least one flitch plate 22. There may be
additional flitch
plates 22 between the beams 20 or to the outside of the beams 20.
[0039] It will be seen by a comparison of the dimensions that the flitch
plates 22 are
considerably narrower in width than that of the beams 20, and are slightly
smaller in thickness
(vertical height) and length than that of the beams 20. Preferably, at least
the top edge of the
flitch plates 22 is recessed below the top surface 12 of the beams 20. The
invention does
contemplate having one or more portions of the flitch plate projecting
outwardly beyond a
surface of the beams and such projecting feature (such as an ear) may function
as an anchor
point, a tie or strapping point for lifting or moving the mat, for example or
securing the mat
to something or something to the mat. The ear could also serve as a
interconnection feature
that may cooperate with a similar feature on an adjacent mat for linking the
mats together
with, for example, a rod extended through aligned openings on the ears.
Recessing the flitch
plates 22 below the surface of the beams 20 serves to keep the flitch plates
22 out of direct
contact with equipment that may be moved against 10, or out of direct contact
with additional
structure to which the assembly 10 is mounted. For example, if the beam
assembly 10 is used
in a construction environment, for instance as support structure for building,
adjacent
structure may be kept out of contact with the flitch plate 22, protecting each
from unnecessary
wear or damage. The recessing of the flitch plate(s) 22 may also serve as a
wear indicator of
the beams 20, such that when the flitch plates 22 become exposed the users
know it is time to
replace the worn beams 20. And even if the flitch plates 22 do become exposed
to the surface,
the structural integrity of the assembly 10 remains intact. It may be
desirable to recess the
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flitch plate(s) 22 from both the top 12 and bottom 14, especially if the
assembly 10 is to be
reversible in nature such that both surfaces may be at times facing upward and
directly
engaged by other structure, vehicles, or the like.
[0040] Another reason to recess the flitch plate(s) 22 from the bottom 14 as
well is to
keep the plates 22 from engaging the surface of adjacent structure on which
the beam
assemblies 10 are supported, especially if there is concern of damage that may
be caused by
direct exposure to metal edges of the flitch plate(s) 22. The length and width
of the flitch
plates 22 is at least 90% that of the length and width of beams 10 and with
the edge surfaces
of the flitch plates 22 preferably being recessed below the exposed top,
bottom and end
surfaces of the beams 20. Beams 20 may also display surprising surface
durability and
toughness, exhibiting a lack of chipping when exposed to other metal
structure. These
properties of the beams 20 may extend the useful life of protecting the flitch
plates 22 in the
assembly 10.
[0041] As illustrated in farther detail in Figure 2, the beams 20 and flitch
plate(s) 22
are ganged together and secured by rods or bolts 24 that extend cross-wise to
the beam
assembly 10 between its opposite sides 18. There are a plurality of such rods
24 shown in the
example. The rods 24 serve to tightly clamp the facing side surfaces of the
beams 20 and
flitch plate(s) 22 into firm frictional engagement with one another, thereby
actively binding
them against lateral and longitudinal movement that serves, together with the
shear load of
the rods 24, to transfer loading applied to the upper surface of the beams 20
to the flitch plates
22 consistently and predictably over the life of the assembly 10. The beams 20
and flitch
plate(s) 22 are provided with cross holes 26, 28 that are positioned and
dimensioned to receive
the rods 24. The rods 24 may be 1 inch rods and preferably #7 Matlock bolts
and the holes
in the beams 20 may measure about 1.06". The holes 28 in the flitch plates 22
are aligned
with the holes 26 of the beams 20.
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[0042] With reference to Figure 3, the holes 28 of the flitch plates 22 are
preferably
slotted in the lengthwise direction with rounded ends and a flat middle of the
slot. The
dimensions of the slotted holes 28 may be, for example, 1.06" in height (i.e.,
the same as the
height dimension of the holes 26 of the beams 20), and a length of 1.5". The
extension of the
holes 28 in the lengthwise direction of the flitch plates 22 is designed to
accommodate the
different coefficients of expansion of the plastic beams 20 and the metal
flitch plates 22,
which may cause the beams 20 to expand disproportionately to that of the
flitch plates 22,
particularly in the lengthwise direction where the extension of the materials
may be the
greatest. The slots thus allow the beams 20 to shift, as necessary, in the
lengthwise direction
due to slight lengthening/retracting of the beams 20 relative to the flitch
plates 22 with
temperature changes so as not to cause binding and potential warpage of the
beams 20 and
flitch plates 22. Because of the relatively small cross section in the
thickness (height)
dimensions between top and bottom surfaces, the degree of
lengthening/retraction is
insignificant and so the height dimension of the slots 28 in the flitch plates
can be the same
as that of the holes 26 in the beams 20, such that their relative positions in
the vertical direction
never change with temperature.
[0043] While the flitch plate 22 and the beam 20 are described above as being
fixed to
each other via the use of the rods 24 to create a frictional engagement
therebetween, the flitch
plate 22 and beam 20 may be secured to each other in other ways. For example,
the flitch
plate 22 may be secured to the beam via the use of adhesives, bonding,
welding, or brazing.
In another approach, a screw may be threaded into one or more beams 20 to
secure the beams
20 and the flitch plate 22. In yet another approach, a nut/bolt mechanism may
be used, in
which at least one nut is threaded over the end of a bolt extending through
the beams 20 and
flitch plate 22.
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[0044] In yet another approach, shown in Figure 4, a mechanical clamp 32 may
be
placed over the assembly 10 to press the beams 20 and flitch plate 22 against
each other.
Similarly, as shown in Figure 5, bands 34 may be applied around the assembly
10 to secure
the beams 20 and flitch plates 22.
[0045] The flitch plate(s) 22 may be fabricated from steel plate stock or
other similarly
performing material, such as fiberglass, of suitable dimensions, examples
which are provided
above.
[0046] The flitch plate(s) 22 may have smooth sides or may, alternatively,
have grip-
enhancing features, such as knurling or other textured features 30, along some
or all of the
side surfaces, as shown in Figure 6. The texturing may be on one or several or
all of the flitch
plates 22. The texturing acts as an enhanced passive load transfer mechanism,
wherein
loading on the surface of the beams 20 is transferred in part to the flitch
plates 22 through the
gripping, friction action of the texturing. The bolts or rods 24 serve as
active load transferring
features wherein the load applied to the beams 20 is born in shear by the
bolts 24 which are
also supported by and transfer load to the flitch plates 22.
[0047] Additionally, or alternatively, the flitch plates 22 may include other
grip
enhancing features. For example, the flitch plates may include projections 40
that extend
outward from the surfaces of the flitch plates 22, as shown in Figure 7. The
projections 40
may be in the form of small spikes, points, hooks, or the like that act to
pierce the adjacent
surface of the beam 20 when compressed together. The projections 40 may be
distributed
substantially across the entire length of the flitch plate 22, or they may be
distributed over
portions of the flitch plate 22, with the remainder of the flitch plate being
smooth or otherwise
textured but free of the projections 40. The projections 40 may act as a
passive load
transferring mechanism, similar to the textured surface described above.

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[0048] As shown in Figure 8, the flitch plate 22 may also include posts 42 or
ribs 44
extending outwardly from the surfaces of the flitch plate 22, in a manner
similar to the
projections 40. The posts 42 or ribs 44 may be larger than the projections 40,
and may be
configured to be received in corresponding holes or grooves formed in the beam
20. The
posts 42 or ribs 44 may therefore act in a manner similar to the rod 24 as an
active load
transfer mechanism. The posts 42 and/or ribs 44 may be distributed along
substantially the
entire length of the flitch plate 22, or they may be limited to particular
locations. As shown
on the left side of Figure 8, the rib 44 extends vertically. However, it will
be appreciated that
the rib 44 could also extend longitudinally along the beam 20, as illustrated
by the right side
of Figure 8, with the cross-section of the rib 44 appearing the same as the
cross-section of the
posts 42 in Figure 8.
[0049] As shown in Figures 9A-D, the flitch plate 22 may have concave outer
surfaces
that mate with corresponding convex outer surfaces of the beam 20.
Alternatively, the flitch
plate 22 may have convex outer surfaces that mate with a concave surface of
the beam 20.
The flitch plate 22 may include both a concave and a convex outer surface on
opposite sides
of the flitch plate 22, with corresponding mating surfaces of the beam. In yet
another
approach, the flitch plate 22 may include outer surfaces that are both concave
and convex to
define a complex curvature, with corresponding mating surfaces of the beam 20.
[0050] Figures 10 and 11 illustrate further alternative embodiments of the
flitch plates
22, wherein the Figure 10 embodiment provides an L-shaped cross section for
the flitch plate
22 and Figure 11 provides a T-shaped cross section. The short legs of the L
and T are designed
to engage a corresponding load-bearing surface of the beam(s) 20 and further
provide load-
transferring support to the beams 20. The short legs can all be arranged on
one side (bottom
of assembly 10) or be staggered to the top and bottom sides of the beam 10,
and are preferably
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recessed below the outer surface(s) of the beams 20. Figures 10 and 11
illustrates the short
legs of the L or T as being on the bottom of the beam assembly 10.
[0051] Figures 12-13 illustrates further alternative embodiments of the flitch
plates 22,
similar to the alternatives of Figures 10 and 11.
[0052] The Figure 12 embodiment provides a C-shaped cross section for the
flitch plate
22. The short legs of the C are designed to engage a corresponding load-
bearing surface of
the beam(s) and further provide load-transferring support to the beams 20. The
short legs can
be arranged on both the top and bottom of the mat, and are preferably recessed
below the
outer surface(s) of the beams 20.
[0053] The Figure 13 embodiment provides an I-shaped cross section (similar to
a
traditional I-beam) for the flitch plate 22. The short legs of the I-shape are
designed to engage
a corresponding load-bearing surface of the beam(s) and further provide load-
transferring
support to the beams 20. The short legs can be arranged on both the top and
bottom of the
mat, and are preferably recessed below the outer surface(s) of the beams 20.
[0054] As shown in Figures 14 and 15, multiple flitch plates 22 may be
disposed
between two of the beams 20, to create shapes similar to the T or I-shaped
cross-sections.
The Figure 14 embodiment utilizes two L-shaped flitch plates 22 to create a T-
shape. The
short legs of the Ls and the resulting T are designed to engage a
corresponding load-bearing
surface of the beam(s) and further provide load-transferring support to the
beams 20. The
short legs can all be arranged on one side (bottom of mat) or be staggered to
the top and
bottom sides of the beam assembly 10, and are preferably recessed below the
outer surface(s)
of the beams 20.
[0055] The Figure 15 embodiment utilizes two C shaped flitch plates 2 to
create an I-
shape. The short legs of the Cs that create the I-shape are designed to engage
a corresponding
load-bearing surface of the beam(s) and further provide load-transferring
support to the beams
12

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20. The short legs can be arranged on both the top and bottom of the mat, and
are preferably
recessed below the outer surface(s) of the beams 20.
[0056] Figure 16 illustrates another embodiment of combined flitch plates, in
which
two L-shapes are combined to create a Z-shape. The short legs of the Ls that
create the Z-
shape are designed to engage a corresponding load-bearing surface of the
beam(s) and further
provide load-transferring support to the beams 20. The short legs can be
arranged on both the
top and bottom of the mat, and are preferably recessed below the outer
surface(s) of the beams
20.
[0057] Figure 17 illustrates another embodiment of the flitch plate, and
provides a Z-
shaped cross section (similar to the two Ls) for the flitch plate 22. The
short legs of the Z-
shape are designed to engage a corresponding load-bearing surface of the
beam(s) and further
provide load-transferring support to the beams 20. The short legs can be
arranged on both the
top and bottom of the mat, and are preferably recessed below the outer
surface(s) of the beams
20.
[0058] Figure 18 illustrates two flat flitch plates 20 that may be combined to
create an
increased thickness flitch plate.
[0059] In each of the above described alternatives, the previously described
features of
the flitch plates 22 will also apply to the alternatives, such as the slots 28
and the surface
feature 30.
[0060] The compressive strength of the composite beams greatly exceeds that of
it
wood counterparts. A surprising synergistic effect is realized when the high
compression
composite beams are paired with the flitch plates in the form of a beam
assembly, wherein
the bending load of the assembled assembly exceeds that of the collective load
capacity of
the beams and flitch plates alone. The high compression beams act to laterally
support the
flitch plates under bending load against beyond what would normally cause the
flitch plate
13

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material to become wavy and buckle. Surprising levels of loading without
failure are realized
by the composite beam assembly described above Rather than buckling under
extreme loads,
the metallic flitch plate(s) will undergo a slight plastic deformation
(stretching/thickening) of
the opposing compressed and tensed edges of the flitch plates.
[0061] As shown in Figure 1, two beams 20 and one flitch plate 22 are
assembled to
define the overall assembly 10, along with the plurality of rods 24 extending
laterally through
the beams 20 and flitch plate 22. However, it will be appreciated that other
quantities and
arrangements of the beam(s) 20 and the flitch plate(s) 22 may also be used to
create different
support and stiffness properties of the assembly.
[0062] As shown in Figure 19, the assembly 10 includes a single beam 20 and
two
flitch plates 22. The flitch plates 22 are arranged on the lateral sides of
the beam 20. As
shown in the Figure 19, the flitch plates 22 are recessed inwardly relative to
the outermost
lateral surfaces of the beam 20. However, in another approach, depending on
the target use
of the assembly, the flitch plates 22 may be disposed over the outermost
lateral surfaces of
the beam, such that the lateral surfaces of the beam 20 are recessed inwardly
from the edges
of the flitch plate 22.
[0063] As shown in Figure 20, the assembly includes two beams 20 and three
flitch
plates, with one flitch plate 22 disposed between the beams 20, similar to the
arrangement of
the Figure 1, and two flitch plates disposed on the outermost lateral sides of
the beam
assembly 10, similar to the arrangement of Figure 19.
[0064] As shown in Figure 21, two flitch plates 22 and two beams 20 may be
used, in
which one lateral side of the assembly 10 is free from an attached flitch
plate, and the other
lateral side of the assembly 10 includes a flitch plate 22.
[0065] As shown in Figure 22, a single beam 20 and a single flitch plate 22 is
assembled
together, with the flitch plate 22 being disposed on one lateral side of the
beam 10. The flitch
14

CA 03081579 2020-05-01
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plate 22 may be inwardly recessed relative to the outermost lateral surface of
the beam 20, or
the flitch plate may be placed over the outermost lateral surface of the beam
20.
[0066] It will be appreciated that further arrangements and quantities of
beams 20 and
flitch plates 22 may be used, including instances in which the lateral stackup
of parts
alternates between flitch plate and beam, or arrangements in which the lateral
stackup has
multiple flitch plates and/or beams adjacent each other and without the
disposition of the
other type of part therebetween.
[0067] Sometimes preservatives such as creosote, chromated copper arsenate
(CCA),
ammoniacal copper zinc arsenate (ACZA) and ammoniacal copper arsenate (ACA)
are used
to treat wood timbers to protect against rot, and these materials may leach
out of the lumber
and into the environment. This does not happen with the assembly 10 made in
accordance
with the invention since its composite beams are not prone to moisture attack,
do not require
any chemical treatment, and do not absorb water or chemicals. The assembly 10
according to
the invention remains inert and unchanged by the environment they occupy.
[0068] The beam assembly 10 may have further plating applied to the surface
and/or
ends and may further have coating applied to its surface(s) such as polymer
coatings.
[0069] It is to be understood that the above drawings and description is
exemplary of
the construction and practice of embodiments of the invention and is not
limiting of the
invention. Rather, the invention is defined in the appended claims which
follow.

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

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Administrative Status

Title Date
Forecasted Issue Date Unavailable
(86) PCT Filing Date 2018-11-03
(87) PCT Publication Date 2019-05-09
(85) National Entry 2020-05-01
Examination Requested 2021-11-04

Abandonment History

Abandonment Date Reason Reinstatement Date
2022-09-26 R86(2) - Failure to Respond 2023-06-29

Maintenance Fee

Last Payment of $210.51 was received on 2023-10-27


 Upcoming maintenance fee amounts

Description Date Amount
Next Payment if standard fee 2024-11-04 $277.00
Next Payment if small entity fee 2024-11-04 $100.00

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Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee 2020-05-01 $400.00 2020-05-01
Maintenance Fee - Application - New Act 2 2020-11-03 $100.00 2020-10-30
Maintenance Fee - Application - New Act 3 2021-11-03 $100.00 2021-10-27
Request for Examination 2023-11-03 $816.00 2021-11-04
Maintenance Fee - Application - New Act 4 2022-11-03 $100.00 2022-10-28
Registration of a document - section 124 2023-06-29 $100.00 2023-06-29
Registration of a document - section 124 2023-06-29 $100.00 2023-06-29
Reinstatement - failure to respond to examiners report 2023-09-26 $210.51 2023-06-29
Maintenance Fee - Application - New Act 5 2023-11-03 $210.51 2023-10-27
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
PLASTIC TIES TECHNOLOGIES LLC
Past Owners on Record
AXION STRUCTURAL INNOVATIONS LLC
PLASTIC TIES FINANCING LLC
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 2020-05-01 2 83
Claims 2020-05-01 4 98
Drawings 2020-05-01 14 745
Description 2020-05-01 15 623
Representative Drawing 2020-05-01 1 33
International Search Report 2020-05-01 10 279
National Entry Request 2020-05-01 6 152
Correspondence 2020-05-13 5 126
Cover Page 2020-06-29 2 57
Office Letter 2020-09-03 1 203
National Entry Request 2020-05-01 7 188
Request for Examination / Special Order 2021-11-04 6 168
Special Order - Green Granted 2021-11-26 1 176
Examiner Requisition 2021-12-09 5 264
Amendment 2022-04-08 14 523
Description 2022-04-08 15 626
Claims 2022-04-08 3 93
Examiner Requisition 2022-05-26 6 298
Special Order - Applicant Revoked 2023-02-16 2 186
Reinstatement / Amendment 2023-06-29 15 512
Claims 2023-06-29 4 183