Polymer construction column and guard plate

Abstract

Securing together a building construction pillar and a fender panel by at least one fastener is disclosed. A post end cap terminates the post. The post has an outer wall defining a pair of plastic fender surfaces and first and second sidewalls, and also has at least one longitudinally extending void space. At least one fastener anchoring and structural reinforcing member is substantially contained within the interior of the post outer wall. In some embodiments, the fastener anchoring and structural reinforcement member includes a plurality of longitudinally extending pillar wall ribs protruding inwardly from the first panel face. In other embodiments, cell partitions are provided, which are parallel and slightly spaced apart from the first and second guard panels. In other embodiments, the internal reinforcement member defines an X-shaped geometry within the compartment. The fastener anchoring and structural reinforcing members are configured to increase stiffness and strength, and also enhance fastener engagement.

Description

Technical Field

[0001] The present invention relates generally to static structures, such as buildings for exemplary purposes, but not limited thereto. In more specific manifestations, improved and cost-effective construction components are used to construct buildings. These construction components desirably facilitate construction while also providing enhanced and beneficial properties. Background Art

[0002] Wood has long been the material of choice for building construction. Construction workers easily cut wood to size using low-cost and much harder hacksaws and carbide saws at the job site, easily and securely fasten wood using low-cost fasteners, wood is extremely strong for a given weight, resists sagging, and is generally low cost. If wood has already been used to construct a building, future renovation projects will be easy to accomplish, also due to the ease of cutting and fastening at the job site.

[0003] Unfortunately, wood is limited in length to the undamaged parts of the tree and to the basic shapes that are easily cut by the sawmill. Even after being properly cut, wood may bend or twist during or after drying in response to changes in ambient humidity. Wood is also easily damaged by water, fungi, and insects such as termites. In addition, wood is not generally available at low cost, particularly in more arid areas of the world and during high demand periods. Although competing natural products such as steel, stone, cement, brick, and ceramic tile have stronger resistance to environmental damage and insect damage, their acquisition is more expensive and more difficult to cut, shape, tighten, and transform afterwards.

[0004] One popular commercial product is polymer wood composite (PWC), which has been developed to strengthen or replace wood, particularly for outdoor decking, but also for many other projects. Exemplary U.S. patents (the teachings of which are incorporated herein by reference) include: U.S. Patent 6,153,293 to Dahl et al., entitled "Extruded wood polymer composite and method of manufacture"; U.S. Patent 6,651,398 to Gregori, entitled "Decking assembly and decking kit with hold-down clip"; and U.S. Patent 6,958,185 to Zehner, entitled "Multilayer synthetic wood component."

[0005] By extruding size-reduced wood fibers, such as sawdust or wood chips, together with polymers, PWC products combine the inherent strength of wood cellulose with the water, fungus and insect resistance of plastics.

[0006] Most commonly, PWCs are extruded into standard sized lumber sizes and are solid products. The resulting boards are very heavy, undesirably expensive, and still susceptible to warping and degradation over time when in contact with moisture or in very humid environments.

[0007] Other artisans have designed plastic products that are, at least in some embodiments, completely wood-free and are likewise intended to reinforce or replace wood. Exemplary U.S. patents (the teachings of which are incorporated herein by reference) include: DiNicola's U.S. Patent 5,783,286, entitled "Hollow-core plastic structural lumber alternative"; Baker's U.S. Patents 6,881,367 and 6,890,637, entitled "Composite materials, articles of manufacture produced therefrom, and methods for their manufacture"; and Carlson et al. U.S. Patent 8,065,848, entitled "Structural member".

[0008] There are several challenges associated with using plastics instead of wood. The first and foremost of these are (but not limited to): the greater cost of plastic materials; the difficulty in manufacturing and cooling the materials without sagging or bending; the difficulty in maintaining the geometric shape after installation in a building without sagging or bending; the recycling of plastics at the end of the building's life; and providing suitable fastener adhesion for plastic lumber. A common technique for improving the structural integrity of plastics is to incorporate fillers, typically fibrous materials. One widely used filler is glass fiber, which is beneficial in terms of strength, sagging, and bending, and in some cases can also improve fastener adhesion. However, glass fiber is very coarse, resulting in greatly accelerated wear and tear in manufacturing and building construction equipment. During cutting and drilling, glass fiber dust can be irritating and harmful, endangering the health of workers in some cases, thus mandating the use of special masks or respirators. In addition, since the fibers are extremely difficult or impossible to reasonably separate from the different component plastics, at the end of their life, fiber fillers also make recycling extremely difficult or even impossible. Therefore, although currently available and known wood-free plastic lumber products address some of these challenges, none of them fully addresses all of them.

[0009] In addition to certain size wood applications, there are other applications where plastic compositions would be expected to provide an alternative to wood and other building materials. Panels are one such area. Exemplary U.S. patents (the teachings of which are incorporated herein by reference) include: U.S. Patent 3,886,705 to Cornland, entitled "Hollow structural panel of extruded plastics material and a composite panel structure formed thereof"; U.S. Patent 5,294,472 to Arnold et al., entitled "Oblique web multiple surface panels fabricated of aromatic polycarbonates";

[0010] De Zen, U.S. Patent 5,706,620, entitled "Thermoplastic structural system and components therefor and method of making same"; Thiagarajan et al., U.S. Patent 8,590,271, entitled "Multi-wall structural components having enhanced radiatransmission capability"; Forbis, U.S. Patent Des 405,545, entitled "Fence plank"; Givoni, U.S. Patent Des 490,544, entitled "Structural panel"; Givoni, U.S. Patent Des 500,370, entitled "Structural panel"; Forbis, U.S. Patent Des 503,000, entitled "Fence panel"; and Amato, U.S. Patent Des 564,106, entitled "Deck panels." These building panels offer opportunities and challenges similar to those described above with reference to dimensional lumber.

[0011] Additional patents of varying relevance, the related teachings and contents of which are incorporated herein by reference, include: U.S. Patent 3,364,638 to Santangelo, entitled "Composite plastic and corrugated panel"; U.S. Patent 3,435,575 to Pottiez, entitled "Process and extruded elements for industrial manufacturing of furniture, furniture components and similar constructions"; U.S. Patent 3,450,593 to Fossier et al., entitled "Panel having rims bonded with glass fibers and polyester resin"; U.S. Patent 3,662,507 to Espeland, entitled "Preformed building wall construction"; U.S. Patent 3,732,138 to Almog, entitled "Panel constructions; Moore, U.S. Patent 3,783,563, entitled "Prefabricated building components"; Winfield et al., U.S. Patent 3,819,466, entitled "Reinforced and insulating building panel"; Rutledge, U.S. Patent 3,948,347, entitled "Acoustical panel"; Kamer, U.S. Patent 3,974,612, entitled "Structural element"; Morrison, U.S. Patent 4,035,536, entitled "Sandwich panel core";U.S. Patent No. 4,441,291 to Sokoler et al., entitled “Panel, in particular for self-supporting roof structures and self-supporting roof structures assembled of such panels”; U.S. Patent No. 4,606,959 to Hillinger, entitled “Honeycomb panel”; U.S. Patent No. 4,718,213 to Butterfield, entitled “Decorative beam assembly”; U.S. Patent No. 4,749,601 to Hillinger, entitled “Composite structure”; U.S. Patent No. 5,030,662 to Banerjie, entitled “Construction material obtained from recycled polyolefins containing other polymers”; U.S. Patent No. 5,052,164 to Sandow, entitled “Method for manufacturing a panel assembly and structure resulting in a therefrom[Method for making panel assemblies and structures obtained therefrom]”; Frankel, U.S. Patent 5,471,809, entitled “Reinforced plastic structural support member[Reinforced plastic structural support member]”; Nosker et al., U.S. Patent 5,789,477, entitled “Composite building materials from recyclable waste[Composite building materials from recyclable waste]”; Phillips et al., U.S. Patent 6,497,956, entitled “Structural recycled plastic lumber[Structural recycled plastic lumber]”;Chen et al., U.S. Patents 6,986,934, 7,169,460, 7,211,310, 7,419,717, 7,763,345, 8,021,741, 8,658,274, and 8,834,992, all entitled "Thermoplastic planks and methods for making the same"; Nosker et al., U.S. Patent 7,795,329, entitled "Use of recycled plastics for structural building forms"; Nosker et al., U.S. Patent 8,629,221, entitled "Compositions and methods of making plastic articles"; Bowman, U.S. Patent 8,752,348, entitled "Composite pre-formed construction articles"; Pettier, U.S. Patent Des 211,517, entitled "Extruded cellular panel for furniture"; Gregori, U.S. Patent Des 423,116, entitled "Decking"; Gregori, U.S. Patent Des 431,658, entitled "Decking"; Thibault et al., U.S. Patent Des 451,612, entitled "Top of a deck member"; Ohanesian, U.S. Patent Des 453,045, entitled "Post for a storage shed"; Gregori, U.S. Patent Des 473,955, entitled "Structural member"; Gregori, U.S. Patent Des 474,286, entitled "Structural member"; Morton et al., U.S. Patent Des 485,373, entitled "Deck plank extrusion"; Takagi's U.S. Patent Des 531,324, entitled "Building board material"; Simko's U.S. Patent Des 564,678, entitled "Construction member";and U.S. Patent Des 585,568 to Kikuchi, entitled "Synthetic board for building purposes.";

[0012] As can be seen, despite the tremendous progress that has been made and the extensive research and development that has been conducted, there remains a need for cost-effective wood lumber alternatives that retain the benefits of wood being easy to cut and fasten, being recyclable, and being easy to clean, while overcoming both the limitations of geometry and the susceptibility to environmental and insect damage and warping.

[0013] In addition to the aforementioned patents, Webster's New Universal Unabridged Dictionary (Second Edition copyright 1983) is incorporated herein by reference in its entirety for definitions of words and terms used herein. Summary of the invention

[0014] In a first manifestation, the present invention is a building construction column comprising a generally continuous plastic outer wall defining a length, a width, a depth, a cross-section transverse to the length, and an interior substantially contained within the generally continuous plastic outer wall; at least one void space extending longitudinally parallel to the generally continuous plastic outer wall and substantially contained within the interior; and at least one fastener anchoring and structural reinforcement member substantially contained within the interior.

[0015] In a second expression, the present invention is a combination of a building construction column, a building construction panel member, and at least one fastener for securing the building construction panel member to the building construction column. The building construction column includes a generally continuous plastic column outer wall, the column outer wall defining a column length, a column width, a column depth, a column cross-section transverse to the column length, and a column interior. The column interior is substantially contained within the generally continuous plastic column outer wall. The plastic column outer wall has a generally planar first panel face parallel to a longitudinal axis and a width axis of the column outer wall, a generally planar second panel face distal from and generally parallel to the generally planar first panel face, a generally planar first column side wall parallel to a longitudinal axis and a depth axis of the column outer wall, a generally planar second side wall distal from and generally parallel to the generally planar first side wall, and at least one void space extending longitudinally parallel to the generally continuous plastic column outer wall and substantially contained within the column interior. The length of the plastic stud outer wall is greater than the depth of the plastic stud outer wall, the cross-section of the substantially continuous plastic stud outer wall defines a rectangle, and the depth of the substantially continuous plastic stud outer wall is greater than the width of the substantially continuous plastic stud outer wall. A plurality of longitudinally extending stud wall ribs protrude inwardly from the substantially planar first panel face. The stud wall ribs are configured to increase stiffness and strength, and are also configured to enhance fastener engagement. The at least one fastener penetrates each of: the building construction panel member, the substantially planar first panel face, and the plurality of longitudinally extending stud wall ribs, thereby securing the building construction panel member to the building construction stud.

[0016] In a third expression, the present invention is a combination of a building construction column and a building construction column end cap. The building construction column includes a generally continuous plastic column outer wall, the column outer wall defining a column length, a column width, a column depth, a column cross-section transverse to the column length, and a column interior substantially contained within the generally continuous plastic column outer wall. At least one void space extends longitudinally parallel to the generally continuous plastic column outer wall and substantially contained within the column interior. A generally planar first panel face is parallel to a longitudinal axis and a width axis of the column outer wall. A generally planar second panel face is distal to and substantially parallel to the generally planar first panel face. A generally planar first column side wall is parallel to a longitudinal axis and a depth axis of the column outer wall. A generally planar second column side wall is distal to and substantially parallel to the generally planar first column side wall. The building construction column end cap includes a termination cap orthogonal to and adjacent to each of the generally planar first panel face, the generally planar second panel face, the generally planar first column side wall, and the generally planar second column side wall. At least one end cap side wall rises from the termination cover and is inserted into the interior of the column. The end cap top surface is bounded by at least one end cap side wall and is away from the termination cover. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The foregoing objects, other objects, advantages and novel features of the present invention may be understood and appreciated by referring to the following detailed description of the present invention in conjunction with the accompanying drawings, in which:

[0018] Figure 1 A preferred embodiment polymer construction stud designed in accordance with the teachings of the present invention is shown from an end view.

[0019] Figure 2 A first alternative embodiment construction column is shown from an end view.

[0020] Figure 3 Shown from the side view Figure 1 The preferred embodiment of the construction column. Figure 4 A second alternative embodiment construction column is shown from an end view.

[0021] Figure 5 A third alternative embodiment construction column is shown from an end view.

[0022] Figure 6 Shown from the side view Figure 4 A second alternative embodiment constructs the columns.

[0023] Figure 7 A fourth alternative embodiment is shown from a top view of the corner of the construction stud and wall.

[0024] Figure 8 A fifth alternative embodiment construction column is shown from an end view.

[0025] Fig. 9 A sixth alternative embodiment construction column is shown from an end view.

[0026] Fig.10 Shown from the side view Figure 8 A fifth alternative embodiment of the construction columns.

[0027] Fig.11 A seventh alternative embodiment construction column is shown from an end view.

[0028] Fig.12 An eighth alternative embodiment construction column is shown from an end view.

[0029] Fig.13 Shown from the side view Fig.11 A seventh alternative embodiment of construction columns.

[0030] Fig.14 A ninth alternative embodiment construction column is shown from an end view.

[0031] Fig.15 A tenth alternative embodiment construction column is shown from an end view.

[0032] Fig.16 Shown from the side view Fig.14 A ninth alternative embodiment of construction columns.

[0033] Fig.17 A preferred embodiment of constructing the guard panel member is shown from an edge view.

[0034] Fig.18 The enlarged side view shows Fig.17 A preferred embodiment of constructing a guard panel member depicts tongues and grooves disposed along opposing edges.

[0035] Fig.19 A first alternative embodiment of constructing the panelling member is shown from an edge view.

[0036] Fig. 20 The enlarged end view shows Fig.19 A first alternative embodiment of constructing a guard panel member depicts tongues and grooves disposed along opposing edges and internal reinforcement members.

[0037] Fig.21 The front elevation view shows Fig.17 The preferred embodiment of the invention is to construct the guard plate members.

[0038] Fig. 22 An eleventh alternative embodiment construction column is shown from an end view.

[0039] Fig.23 A twelfth alternative embodiment construction column is shown from an end view.

[0040] Fig.24 The eleventh alternative embodiment construction stud is shown from a horizontal cross-sectional view with screws attaching the sheet to the stud.

[0041] Fig.25 Shown Fig.24 An enlarged partial cross-sectional view of .

[0042] Fig.25a Shown Fig.25 An enlarged partial cross-sectional view of a wall structure in which an applied force drives the fastener into the wall stud, thereby expanding the ribs.

[0043] Fig.25b Shown Fig.25 An enlarged partial cross-sectional view of an embodiment of the present invention in which an applied force pulls the fastener out of the wall stud, thereby causing the rib to contract around the fastener.

[0044] Fig.26 The preferred embodiment column cap is shown from a projection view.

[0045] Fig. 27 An alternative embodiment stud cap is shown from a projection view. DETAILED DESCRIPTION

[0046] As manifested in a preferred embodiment, the present invention provides a polymeric construction component having a generally continuous outer wall having at least one and preferably a plurality of longitudinally extending hollow portions or void spaces therein, and providing a structurally reinforced and fastener-anchored internal web which, in some embodiments, is spaced apart to define the hollow portions.

[0047] exist Figure 1 and Figure 3 In the illustrated preferred embodiment of the invention, construction stud 10 includes an outer wall 11, at least one secondary fastener anchor and internal reinforcement member 12, and a void space 14. In the preferred embodiment, at least two secondary fastener anchor and internal reinforcement members 12 are provided and arranged to define an X-shaped cross-section therebetween, thereby creating a semi-open profile having an excellent strength-to-weight ratio.

[0048] Although shown as having a substantially constant thickness, in some embodiments, the outer wall 11 will be slightly thicker on the narrower longitudinally extending face than on the wider face. In these embodiments, the additional wall thickness will be selected to assist in the fixation of nails and screws. Also for exemplary and non-limiting purposes, a 2X4 size stud has an actual dimension of 1.5X 3.5 inches. The 1.5 inch face is generally in contact with the wall, ceiling, etc. Therefore, fasteners securing drywall or other panels or sheathing will pass through the 1.5 inch face. The additional thickness on the 1.5 inch face will then provide a somewhat more secure attachment. As referenced in Figure 1 The outer wall 11 includes a generally planar first guard plate face 11a, which is parallel to the longitudinal axis and the width axis of the outer wall. A generally planar second guard plate face 11b is distal to and generally parallel to the generally planar first guard plate face 11a. The side walls 11c, 11d are perpendicular to the first guard plate face 11a and the second guard plate face 11b, and include generally planar faces parallel to the longitudinal axis and the depth axis of the outer wall 11.

[0049] The above-mentioned definitions of the width axis and the depth axis are provided only for the convenience of communicating the various faces of the outer wall 11, and when the column 10 is used as a vertical wall column, these definitions are selected herein to correspond to the building wall. In such a case, the height axis of the building wall is parallel to the longitudinal axis of the outer wall 11, the width axis of the building wall is parallel to the width axis of the outer wall 11, and the depth axis or thickness axis of the building wall is parallel to the depth axis of the outer wall 11. However, such marking is only for convenience and understanding, and should not be understood as limiting the present invention in any way.

[0050] The interior of the preferred embodiment construction stud 10 includes two secondary fastener anchors and internal reinforcement members 12 arranged in an X-shaped pattern, thereby creating four void spaces 14, each of which has a triangular prism geometry. In the preferred embodiment construction stud 10, the spaces 14 between the internal reinforcement members 12 are open to the atmosphere. Although not preferred for a variety of reasons (including more difficult initial manufacturing, more difficult installation by construction workers, and more difficult recycling at the end of the building's life), in some alternative embodiments, these spaces are filled with a suitable solid material or foam material, which, for exemplary and non-limiting purposes, includes wood, resins and plastics, metals, ceramic or cementitious materials, or even combinations or composites of the above materials. In other additional alternative embodiments, these spaces are only partially filled with additional material (such as at the ends or at periodic or predetermined intermediate locations).

[0051] The internal reinforcement members 12 help reduce the transfer of heat and sound while also improving the strength to weight ratio. In addition, these internal reinforcement members 12 provide a second anchor point for fasteners installed into the preferred embodiment construction column 10. This is extremely beneficial in ensuring that the fasteners are securely anchored by providing additional grip to help prevent the fasteners from coming loose. Although in some embodiments, one pair of internal reinforcement members 12 arranged in an X-shaped pattern may be sufficient, the preferred embodiment construction column 10 is instead provided with three pairs of internal reinforcement members 12, each pair arranged in an X-shaped pattern. Each pair is separated from an adjacent pair by a cell divider and internal reinforcement members 13, which both add reinforcement strength to the preferred embodiment construction column 10 and divide the interior of the preferred embodiment construction column 10 into several smaller sections.

[0052] One particularly significant benefit of subdividing the interior space within the preferred embodiment construction stud 10 is that a fastener of reasonable length is more likely to penetrate not only the exterior wall 11, but also at least one, and potentially several, interior reinforcement members 12, 13. As already noted above, achieving this is extremely beneficial in ensuring that the fastener is securely anchored and remains securely anchored.

[0053] The preferred embodiment construction column 10 is preferably manufactured entirely and exclusively of plastic (including any suitable combination of virgin or recycled content) and is particularly suitable for interior non-load bearing applications. In the most preferred embodiment, the plastic component forming the majority of the column 10 is homogeneous and uniform, which greatly facilitates recycling. However, it will be understood that even in some most preferred embodiments where the majority of the column 10 is homogeneous and uniform, a nominal surface coating, treatment, or finish of a different composition or lacking homogeneity or uniformity relative to the majority of the column 10 will be applied.

[0054] The benefit of plastic is that it is not always subject to price fluctuations to the same degree and time as wood and other natural materials. In addition, plastic is fully recyclable, especially when used internally and therefore not exposed to a lot of UV light. Whether when recycling construction remnants or demolishing or renovating buildings after a few years, the preferred material can be ground and reused or recycled for alternative products or concrete fill. Therefore, plastic can present potential carbon compensation in some life cycles. Moreover, plastic is not a food source for pests and fungi, nor does it have problems with exposure to water or bending due to changes in moisture content or humidity. Plastic is also easy to wash and clean on site. This makes plastic particularly desirable in areas with high rainfall, high groundwater levels, other risks of moisture or water infiltration or exposure, insect activity, or lack of available wood.

[0055] However, in some alternative embodiments, there will be requirements and goals that would cause such alternative embodiments to include plastics mixed with other materials.For exemplary and non-limiting purposes, some load-bearing applications may benefit from incorporating glass or other reinforcing fibers.

[0056] In some embodiments, to aid in securing the preferred embodiment construction posts 10 adjacent the ends, caps are provided that surround and reinforce the ends and adjacent structures to which the posts are secured. Fig.26 and Fig. 27 1 and 2. In other embodiments, where a predetermined length is known and desired (no further cutting is done), the ends are filled or reinforced with additional material. In still other embodiments, where a predetermined length is known and desired (including cutting into intermediate lengths), the middle portion of the void space 14 is selectively filled or otherwise reinforced to accommodate multiple predetermined potential lengths used or desired at the job site.

[0057] A plurality of different embodiments of the device designed according to the present invention have been shown in a plurality of different figures. These embodiments are distinguished by the hundreds and tens digits, and the various components in each embodiment are represented by the units digits. However, many components between the embodiments are alike or similar, and therefore the units digit numbering has been retained as much as possible, so that it is easier to identify consistent, identical or similar functions between the embodiments. If not otherwise specified, those skilled in the art will easily recognize the similarity, and understand that according to this teaching, in many cases, the components with the same units digit numbering can be replaced from one embodiment to another embodiment, unless such replacement will destroy the operation of the embodiment. Therefore, those skilled in the art will easily determine the functions and operations of the many components shown herein, without unnecessary additional description. In addition, a plurality of different alternative embodiments will be shown that will be understood as the features applicable to other embodiments, and those with reasonable skills in the art will easily determine the relevance and desirability of these features after viewing this disclosure.

[0058] Figure 1 There is shown a profile view or open end view of a preferred embodiment construction stud 10, which may be manufactured, for example, in the familiar 2X4 dimensional lumber geometry. Figure 2 A similar profile view or open end view of an alternative embodiment construction stud 20 is shown, which alternative embodiment construction stud may be manufactured, for example, in the familiar 2X 6 dimensional lumber geometry. Although the two embodiments are otherwise very similar, due to the larger 5.5 inch size, the alternative embodiment construction stud 20 has a total of four cells, each with pairs of internal reinforcement members 22 arranged in an X-shaped pattern. Each pair is separated from an adjacent pair by a cell divider and an internal reinforcement member 23, with a total of three such internal reinforcement members depicted.

[0059] Figure 3 A simple rectangular side view of a preferred embodiment construction stud 10 is shown, showing a generally planar first panel face 11a, and in this view, the stud 10 is laid horizontally on the page. As shown, although the length of the preferred embodiment construction stud 10 is indefinite, typical standard lengths for exemplary and non-limiting purposes may be 96 inches, 120 inches, and 144 inches. The side view of the alternative embodiment construction stud 20 is the same.

[0060] Figure 4 and Figure 6A second alternative embodiment construction stud 30 is shown. Although most components are similar or identical to those of the preferred embodiment construction stud 10, the second alternative embodiment construction stud 30 additionally includes a tab 36 that can be used to eliminate the need for a stud in a corner installation. The second alternative embodiment construction stud 30 and Figure 5 The third alternative embodiment construction studs 40 shown in FIG. 1 each have the tabs 36, 46 extending in the plane of the 1.5 inch face. The tabs 36, 46 eliminate studs in corners by creating proper spacing and contact for drywall, etc. in the corners.

[0061] Figure 7 The fourth alternative embodiment of the construction column 30' is shown with Figure 4 The fourth alternative embodiment construction stud 30' is similar and therefore not separately numbered, but wherein the tab 36' still originates at the corner between the plane of the 1.5 inch face and the plane of the 3.5 inch face. However, in this fourth alternative embodiment construction stud 30', the tab is parallel to the plane of the 3.5 inch face. Again, this tab 36' is configured to eliminate studs in corners by creating proper spacing and contact for drywall, etc. in the corner.

[0062] Figure 8 and Fig.10 A fifth alternative embodiment construction stud 50 is shown. While most components are again similar or identical to those of the preferred embodiment construction stud 10, the fifth alternative embodiment construction stud 50 is designed as a top stud and, therefore, includes a pair of tabs 56. The tabs 56 are arranged to extend in the plane of the side walls 51c and 51d and allow drywall to abut the stud and provide space for trusses or ceiling joists to collapse and retract. Figure 8 and Fig. 9 The fifth alternative embodiment construction stud 50 and the sixth alternative embodiment construction stud 60 shown in FIGS. 1 and 10 , respectively, each have such tabs 56 , 66 extending in the plane of the side wall.

[0063] Fig.11 and Fig.13A seventh alternative embodiment construction stud 70 is shown. In this embodiment, the secondary fastener anchoring structure and internal reinforcement 12 and cell divider and internal reinforcement member 13 of the preferred embodiment construction stud 10 have been replaced by an "I" shaped geometric internal structure that includes two internal reinforcement members 75 that extend in a plane approximately parallel to and relatively close to the respective generally planar first and second sheathing faces 71a, 71b. A long central internal reinforcement member 77 extends in a plane roughly centered between the two side walls 71c and 71d and parallel to the two side walls. In this seventh alternative embodiment construction stud 70, a fastener driven into the stud 70 from the generally planar first sheathing face 71a will first pass through the outer wall 71, then through the small gap 74, and then will penetrate the adjacent internal reinforcement member 75. As already described above, this will significantly help ensure that nails, screws, and other fasteners have a permanent retention. The eighth alternative embodiment construction column 80 has a very similar internal reinforcement member in an "I" shaped geometry, but in an exemplary 2X 6 configuration instead of Fig.11 An exemplary 2X 4 specification.

[0064] Fig.14 and Fig.16 The ninth alternative embodiment of the construction column 90 and Fig.15 Tenth alternative embodiment construction posts 100 are shown each having a geometry similar to that of the seventh alternative embodiment construction post 70. However, instead of having a single long centrally located internal reinforcement member 77, the ninth alternative embodiment construction post 90 has a pair of long internal reinforcement members 97, each of which is spaced a relatively small distance from the nearest side wall 91c, 91d. These construction posts 90, 100 provide greatly improved fastener retention, whether the fastener is driven from the panel face 91a, 91b, 101a, 101b or from the side wall 91c, 91d, 101c, 101d.

[0065] Fig.17 , Fig.18 ,as well as Fig.21 A preferred embodiment construction sheathing panel 200 is shown. As depicted, the panel 200 has a basic sheet-like geometry with relatively large length and width and relatively much smaller thickness or depth. For exemplary and non-limiting purposes, exemplary dimensions of the preferred embodiment construction sheathing 200 would include: 4'X8'X1 / 2" or 5 / 8" for walls and floors; or 2'X12'X1 / 2" for ceilings. As shown in Fig.18As best seen in the preferred embodiment of the construction panel 200, preferably includes tongues 206 and mating grooves 208 disposed along opposite edges, most commonly the lengthwise edges. The tongues 206 and grooves 208 operate in a known manner, thereby enabling the installer to abut the sheets against each other in an interlocking manner for better securing and sealing. Although not shown, in some embodiments, construction panel members designed in accordance with the teachings of the present invention have slots to support structural requirements.

[0066] Fig.19 and Fig. 20 A first alternative embodiment construction guard panel 210 is shown having the same or similar tongues 216 and mating grooves 218. However, in this first alternative embodiment construction guard panel 210, an internal geometry similar to that of the preferred embodiment construction stud 10 is preferably provided. An outer wall 211 forms an outer perimeter around a plurality of cells (defined by cell dividers and internal reinforcement members 213), and a pair of secondary fastener anchoring structures and internal reinforcement members 212 are provided within each cell, each functioning in a manner similar to similar components found in the preferred embodiment construction stud 10. A thicker outer face 219 may be provided in some embodiments (including the first alternative embodiment construction guard panel 210) as needed or desired for a particular application. In other embodiments, the outer wall 211 will instead have a constant thickness throughout.

[0067] Although the preferred embodiment studs and the alternative embodiment studs may have any suitable opacity, the construction guard panel members 200, 210 are preferably transparent or translucent. This allows a carpenter or other person constructing a structure to save time by being able to see through the guard panel to the studs (such as the preferred embodiment construction studs 10), and then be able to fasten the guard panel to the studs without measuring and estimating the location of the studs and without blind fastening. In addition to the transparency or translucency of the panel members, in most embodiments, the guard panel will also be paintable to achieve opacity, custom coloring or decoration, and reduce or prevent ultraviolet damage to plastics. This also provides potential labor savings by reducing the need to tape and cover gypsum board with paint and texture.

[0068] Fig. 22 , Fig.24 ,as well as Fig.25 An eleventh alternative embodiment construction stud 110 is shown. Rather than having spanning internal reinforcement members, the eleventh alternative embodiment construction stud 110 provides inwardly projecting wall ribs 118 that provide increased stiffness and strength without increasing overall wall thickness, thereby keeping overall weight and material consumption to a minimum. Fig. 22 , Fig.24 ,as well as Fig.25 The wall ribs 118 shown in FIG. 1 are only provided on the panel faces 111a, 111b, which are the surfaces to which the drywall or panels will be attached. However, in some alternative embodiments, more and fewer interior faces of the studs 110 will be provided with the wall ribs 118.

[0069] like Fig.25a As shown in the figure (which is greatly exaggerated to convey what would otherwise be difficult to convey visually), when a fastener (such as a screw 2, or in an alternative embodiment a nail, or other penetrating fastener) is driven into the panel face 111a, both the panel face 111a and the wall ribs 118 will be urged to flex or deform toward the opposing panel face 111b. This flexing means that the panel face 111a will tend to bend so that the portion of the wall ribs 118 that protrudes most into the interior of the stud 110 will be separated from similar portions adjacent to the wall ribs 118. The net effect of separating adjacent wall ribs 118 will allow the fastener 2 to penetrate into the stud 110 relatively more easily with minimal additional interference from the wall ribs 118 than if the first panel face 111a had not been flexed.

[0070] However, if Fig.25b (This figure is also greatly exaggerated to convey what would otherwise be difficult to convey visually) As shown, when a fastener, such as a screw 2, is pulled away from the stud 110, such as when a force is applied that might tend to pull out drywall, sheet 200, or other object anchored to the stud 110, the resulting force will tend to cause the sheathing face 111a to arc away from the opposing sheathing face 111b. This movement, even if slight, will cause the portions of the ribs 118 that protrude most toward the center of the stud 110 to be pulled closer to similar portions of the adjacent ribs 118. The net effect of drawing adjacent ribs 118 together will increase the force required to pull the fastener out of the stud 110, thereby creating additional interference from the ribs 118. Thus, the addition of the ribs 118 increases the force required to insert the fastener less than the same ribs increase the force required to extract or pull the fastener out of the stud 110. In addition, the ribs require less material and weigh less overall than simply thickening the outer wall of the stud 110.

[0071] As will be appreciated, in some embodiments, each of the materials, dimensions, and overall geometry of the wall ribs 118, the first guard plate face 111a, and the fastener 2 can be varied to meet the needs of a particular application. For exemplary and non-limiting purposes, the width of the valleys between the protruding teeth and the width of the protruding teeth can each be increased or decreased, such as will be appropriately increased or decreased to work best with a particular size or type of fastener.

[0072] Fig.23The twelfth alternative embodiment construction stud 120 shown in FIG. 1 incorporates wall ribs 128 having similar geometry and function as the wall ribs 118. These wall ribs 121 are further combined with a pair of internal reinforcement members 125, each of which is spaced a relatively small distance from an adjacent ribbed wall 121. The internal reinforcement members 125 have similar geometry and function as the internal reinforcement members 75 of the seventh alternative embodiment construction stud 70, so that the stud 120 provides even greater holding force and structural rigidity. As can be readily apparent, these construction studs 110, 120 provide improved fastener retention.

[0073] Fig.26 and Fig. 27 Preferred and alternative embodiment stud caps 300, 310 are shown. In these embodiments, both stud caps 300, 310 have a solid body that caps the end of a stud. For exemplary purposes, stud cap 300 is configured to terminate stud 120, while stud cap 310 is configured to terminate stud 110. As will be described below, when the stud cap is properly placed in the end of the stud, fasteners can be driven into the solid core of the stud cap, thereby allowing a carpenter to install fasteners from nearly any direction or angle, which is a common practice for wood studs.

[0074] Both have similar features, including top surfaces 302, 312; side walls 306, 316; ribs 308, 318; and end caps 304, 314. As previously described, in the preferred embodiment of the column end caps 300, 310, the volume within the space defined by the top surfaces 302, 312, side walls 306, 316, and end caps 304, 314 is solid. However, in some alternative embodiments, there will be a limited air space, and in still other alternative embodiments, there will be a predetermined web similar to the internal reinforcement members (such as 12, 13, 75, and 77).

[0075] As from Fig.26 and Fig. 27 As is apparent from inspection of the sidewalls 316, the sidewalls 316 define a volume that extends across substantially the entirety of the termination cap 314, leaving only the termination cap 314 at Fig. 27 The small lip or overhang is configured to engage with the outer wall 111 when the column cap 310 is fully and properly inserted into the end of the column 110, thereby preventing the column cap 310 from falling into the column 110 and beyond the end cap 314. Because the column 120 has additional internal reinforcement members 125 that reduce the open void space 124 to a smaller cross-section than the cross-section of the void 114, the sidewall 306 leaves a much larger lip or overhang on the exposed end cap 304.

[0076] In addition, the side wall 316 forms an orthogonal plane relative to the top surface 312 and the end cap 314. In contrast, the side wall 306 is not a plane, so the top surface 302 is slightly smaller. The rib 318 is configured to engage with the inner part of the outer wall 111, thereby producing a slight plastic deformation therebetween in the manner of a cork in a bottle to ensure a secure fit therebetween. However, like a cork, the slightly smaller top surface 302 allows the face to be inserted more easily and requires less precise alignment before engaging the rib 308 with the outer wall 121, thereby making installation less difficult to a certain extent.

[0077] The features that distinguish the column end caps 300, 310 from each other are provided for exemplary purposes and are not mutually exclusive. In other words, and for exemplary and non-limiting purposes only, in some alternative embodiments, a larger lip defined by the end cap 304 will be used in combination with a planar and orthogonally arranged side wall 316. Further, although the column end caps 300, 310 are each shown as having a top surface 302, 312 that is generally planar and parallel to the termination caps 304, 314, in some alternative embodiments, the top surfaces 302, 312 are provided with recesses or cutouts corresponding to internal webs formed by features such as: secondary fastener anchoring structures and internal reinforcement members 12, 22, 32, 42, 52, 62, 72, 82, 92, 102; cell dividers and internal reinforcement members 13, 23, 33, 43, 53, 63; internal reinforcement members 75, 85, 95, 105, 125; long central internal reinforcement members 77, 87, 97, 107; and wall ribs 118, 128.

[0078] As will be apparent from the foregoing, various embodiments of the present invention utilize only plastic building components. There are two major components of the plastic building material, the first being the structural studs and the second being the sheathing. Both structures include an exterior wall and are hollow with additional interior reinforcements for both structural reinforcement and improved fastener retention. The combination of the exterior wall, interior reinforcements, and the voids therein slows down the transfer of heat and sound while also providing a good strength to weight ratio and less material usage. Furthermore, the only material used is plastic, the benefits of which have been described in detail above.

[0079] The specific plastic used has a number of requirements. The first is that the type of plastic used will most preferably have low sag. Sag is the cold flow of the plastic which can cause the plastic to permanently deform. In addition, the plastic will preferably interact with the selected fasteners in such a way as to prevent the fasteners, screws, and nails (for exemplary and non-limiting purposes) from releasing or retracting when the structure is loaded by events such as: opening and closing doors and windows; general bumps and strikes against walls; and in the case of load-bearing installations, wind, rain, and snow.

[0080] Industrial Applicability

[0081] Exemplary embodiments of the present invention address the deficiencies of the prior art by providing: a homogenous and unitary plastic building construction stud having a generally continuous plastic outer wall; at least one void space extending longitudinally parallel to the generally continuous plastic outer wall and substantially contained within an interior; and at least one fastener anchoring and structural reinforcement member substantially contained within the interior.

[0082] The present invention and preferred and alternative embodiments have been developed with multiple objectives in mind. Although not all of these objectives can be found in every embodiment, these objectives provide a sense of the general intent and many possible benefits that can be obtained from embodiments of the present invention.

[0083] A first object of the present invention is to provide improved and cost-effective construction components for building buildings. As a corollary, an object of the present invention is to require less material for a given length and strength requirement, which is beneficial both to material cost and during manufacture, since generally less material cools faster. A second object of the present invention is to make these construction components conducive to on-site building construction and renovation by making it easy and safe for construction workers to cut and otherwise work on them, and easy to clean when necessary. As a corollary, an object of the present invention is to use materials that are not harmful to construction workers during building construction. Another object of the present invention is to reduce the susceptibility to environmental damage and insect damage. Another object of the present invention is to make these construction components easy to recycle at the end of the building's life. Yet another object of the present invention is to provide suitable fastener adhesion.

[0084] Although the foregoing details what is considered to be the preferred embodiment of the present invention, it is not intended to cause substantial limitations to the scope of the claimed invention. Further, features and design alternatives that are obvious to those skilled in the art are considered to be incorporated herein. The scope of the present invention is set forth and particularly described in the claims below.

Claims

1. A building construction column, the building construction column comprising: a generally continuous plastic outer wall defining a length, a width, a depth, a cross-section transverse to said length, and an interior substantially contained within said generally continuous plastic outer wall; at least one void space extending longitudinally parallel to said generally continuous plastic outer wall and substantially contained within said interior; and at least one fastener anchoring and structural reinforcement member substantially contained within said interior.

2. The building construction column according to claim 1, wherein: The generally continuous plastic outer wall and the at least one fastener anchoring and structural reinforcement member comprise a homogeneous composition.

3. The building construction column according to claim 1, wherein: The plastic outer wall further comprises: a first generally planar guard panel face parallel to the longitudinal axis and the width axis of the outer wall; a second generally planar guard plate surface, the second guard plate surface being remote from and generally parallel to the first generally planar guard plate surface; a generally planar first sidewall parallel to the longitudinal axis and the depth axis of the outer wall; and A second generally planar sidewall is distal to and generally parallel to the first generally planar sidewall.

4. The building construction column according to claim 3, wherein: The length of the plastic outer wall is greater than the depth of the plastic outer wall, a cross-section of the substantially continuous plastic outer wall defines a rectangle, and the depth of the substantially continuous plastic outer wall is greater than the width of the substantially continuous plastic outer wall.

5. The building construction column according to claim 1, wherein: The at least one fastener anchor and structural reinforcement member is integral with the substantially continuous plastic outer wall 6. The building construction column according to claim 4, wherein: The at least one fastener anchoring and structural reinforcement member is substantially contained within the interior and divides the interior into a plurality of void spaces.

7. The building construction column according to claim 6, further comprising: a first cell divider and an internal reinforcement member intermediate between the first generally planar panel face and the second generally planar panel face and relatively closer to the first generally planar panel face than to the second generally planar panel face; as well as A second cell divider and internal reinforcement member are intermediate between the first cell divider and the second generally planar panel face.

8. The building construction column according to claim 6, wherein: The at least one fastener anchor and structural reinforcement member further includes at least one pair of fastener anchor and structural reinforcement members arranged to define an X-shaped cross-section.

9. The building construction column according to claim 7, wherein: The at least one fastener anchoring and structural reinforcement member further comprises: a first pair of fastener anchoring and structural reinforcement members arranged to define an X-shaped cross-section within a first interior cell space defined by said first generally planar panel face, said first cell divider, said first generally planar sidewall, and said second generally planar sidewall; and A second pair of fastener anchors and structural reinforcement members are arranged to define an X-shaped cross-section within a second interior chamber space defined by the generally planar second guard plate surface, the second chamber divider, the generally planar first side wall, and the generally planar second side wall.

10. The building construction column of claim 1, further comprising a plurality of longitudinally extending wall ribs projecting inwardly from the outer wall, the wall ribs being configured to increase stiffness and strength and further configured to enhance fastener engagement.

11. The building construction column of claim 4, further comprising a plurality of longitudinally extending wall ribs projecting inwardly from the generally planar first sheathing surface, the wall ribs being configured to increase rigidity and strength and further configured to enhance fastener engagement.

12. The building construction column of claim 1, further comprising at least one tab protruding outside of the outer wall and configured to engage a sheathing.

13. The building construction column of claim 7, further comprising a generally planar third cell divider and internal reinforcement member extending between the first cell divider and internal reinforcement member and the second cell divider and internal reinforcement member, the generally planar third cell divider and internal reinforcement member being parallel to the generally planar first sidewall.

14. The building construction column according to claim 13, further comprising: A generally planar fourth chamber divider and internal reinforcement member extending between the first chamber divider and internal reinforcement member and the second chamber divider and internal reinforcement member, the generally planar fourth chamber divider and internal reinforcement member being parallel to the generally planar second side wall; wherein the generally planar third chamber divider is adjacent to the generally planar first side wall and distal to the generally planar fourth chamber divider, and wherein the generally planar fourth chamber divider is adjacent to the generally planar second side wall and distal to the generally planar third chamber divider.

15. A combination of a building construction column, a building construction panel member, and at least one fastener for fastening the building construction panel member to the building construction column, The building construction column comprises: A generally continuous plastic column outer wall defining a column length, a column width, a column depth, a column cross-section transverse to the column length, and a column interior substantially contained within the generally continuous plastic column outer wall, the plastic column outer wall having a first substantially planar panel surface parallel to the longitudinal axis and the width axis of the outer wall of the column, a second generally planar panel face remote from and generally parallel to the first generally planar panel face, a substantially planar first side wall of the column parallel to the longitudinal axis and the depth axis of the outer wall of the column, a second generally planar sidewall distal from and generally parallel to the first generally planar sidewall, and at least one void space extending longitudinally parallel to the generally continuous plastic column outer wall and substantially contained within the column interior, wherein the length of the plastic column outer wall is greater than the depth of the plastic column outer wall, a cross-section of the substantially continuous plastic column outer wall defines a rectangle, and the depth of the substantially continuous plastic column outer wall is greater than the width of the substantially continuous plastic column outer wall; and a plurality of longitudinally extending column wall ribs projecting inwardly from the generally planar first panel face, the column wall ribs being configured to increase stiffness and strength and further configured to enhance fastener engagement; the at least one fastener penetrating each of: the building construction panel piece, the generally planar first panel face, and the plurality of longitudinally extending column wall ribs, thereby securing the building construction panel piece to the building construction column.

16. The combination of a building construction column, a building construction panel member, and at least one fastener as claimed in claim 15, wherein: The building construction guard plate member comprises: A substantially continuous plastic panel outer wall defining a panel length, a panel width, a panel depth, a panel cross-section transverse to the panel length, and a panel interior substantially contained within the substantially continuous plastic panel outer wall, the panel outer wall having a first substantially planar chamber face parallel to the longitudinal axis and the width axis of the outer wall, a generally planar wall cavity face distal from and generally parallel to the generally planar chamber panel face, a generally planar first panel side wall parallel to the longitudinal axis and the depth axis of the panel exterior wall, and a generally planar second panel side wall distal from and generally parallel to the generally planar first panel side wall; a first generally planar guard panel cell divider and an internal reinforcement member intermediate between the first generally planar guard panel sidewall and the second generally planar guard panel sidewall and relatively closer to the first generally planar guard panel sidewall than to the second generally planar guard panel sidewall; a second generally planar guard panel cell divider and internal reinforcement member intermediate between said first guard panel cell divider and internal reinforcement member and said second generally planar guard panel sidewall; a first pair of generally planar panel fastener anchoring and structural reinforcement members arranged to define an X-shaped cross-section within a panel first interior cell space defined by said generally planar cell face, said first panel cell divider, said generally planar first panel sidewall, and said generally planar second panel sidewall; a second pair of fastener anchoring and structural reinforcement members arranged to define an X-shaped cross-section within a panel second interior cell space defined by said generally planar cell face, said second panel cell divider, said generally planar first panel sidewall, and said generally planar wall cavity face; and A plurality of guard plate gap spaces extending longitudinally parallel to the length of the guard plate and substantially contained within the guard plate, wherein the length of the plastic guard plate outer wall is greater than the depth of the plastic guard plate outer wall, the cross-section of the substantially continuous plastic guard plate outer wall defines a rectangle, and the depth of the substantially continuous plastic guard plate outer wall is less than the width of the substantially continuous plastic guard plate outer wall.

17. The combination of a building construction column and a building construction panel member as claimed in claim 15, wherein: The generally planar first chamber face has a depth parallel to the guard plate depth that is greater than a depth of the generally planar wall cavity face parallel to the guard plate depth.

18. A combination of a construction column and an end cap of the construction column, the construction column comprising: a generally continuous plastic column outer wall defining a column length, a column width, a column depth, a column cross-section transverse to the column length, and a column interior substantially contained within the generally continuous plastic column outer wall; at least one void space extending longitudinally parallel to the generally continuous plastic stud exterior wall and substantially contained within the stud interior; a generally planar first panel face parallel to the longitudinal axis and the width axis of the stud exterior wall; a second generally planar guard plate surface, the second guard plate surface being remote from and generally parallel to the first generally planar guard plate surface; a first generally planar column sidewall parallel to the longitudinal axis and the depth axis of the column outer wall; as well as a second generally planar column sidewall, the second column sidewall being distal from and generally parallel to the first generally planar column sidewall; The end cap of the building construction column comprises: a termination cap orthogonal to and adjacent to each of said first generally planar fender face, said second generally planar fender face, said first generally planar column sidewall, and said second generally planar column sidewall; at least one end cap side wall, the at least one end cap side wall standing from the end cover and inserted into the interior of the column; and An end cap top surface is bounded by the at least one end cap side wall and is distal to the terminating cover.

19. The combination of a building construction column and a building construction column end cap as claimed in claim 18, wherein: The at least one end cap sidewall further includes four sidewalls, each sidewall being orthogonal to each other and to the termination cover.

20. The combination of a building construction column and a building construction column end cap as claimed in claim 18, wherein: The at least one end cap sidewall further comprises: four side walls, each of the four side walls standing from the terminating cover and defining a volume enclosed by the four side walls, the terminating cover, and the end cap top surface; wherein the volume has a volume cross-section transverse to a longitudinal axis of the outer wall of the column; and Wherein, the area of ​​the volume cross section adjacent to the termination cover is larger than the area adjacent to the top surface of the end cap.

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