Structural element

Abstract

This invention relates to a structural element and more particularly, but not exclusively, to a structural element for defining a high strength, light weight support element and nailer strip. The structural element 1 comprises a body which is made from a first material and its shape resembles a structural channel 2 or a lipped channel which has a retaining formation 4. A complementary shaped inset 5 which is retained within the structural channel 2 by the retaining formations. The inset 5 is made from a material which is softer than the material of which the structural channel 2 is made. A cavity 3 in the inset 5 is found between the inset 5 and an inner wall of the structural channel 2. This cavity 3 specifically forms part of the inset to lessen the amount of material used and consequently reducing the weight of the structural element 1.

Description

[0001] STRUCTURAL ELEMENT

[0002] FIELD OF THE INVENTION

[0003] This invention relates to a structural element and more particularly, but not exclusively, to a structural element for defining a high strength, light weight support element and nailer strip.

[0004] BACKGROUND TO THE INVENTION

[0005] The construction industry has long grappled with the challenge of securely fastening various building materials, such as siding, trim, and panelling, to structural substrates or posts.

[0006] Traditional methods often involve directly nailing or screwing these materials to the substrate, which can lead to several complications. These complications include insufficient grip, potential damage to the materials, and compromised structural integrity over time.

[0007] Nailer strips are used to receive a nail which is driven through a panel that needs to be supported. A nailer strip can be manufactured from a variety of materials, including wood, metal, or composite materials, depending on the specific application requirements. Its profile may be dependent on the length of the nail which it needs to receive, and too narrow profiles may cause the structure to lose strength over long lengths.

[0008] As known in the art, various support structures such as fence posts or floor substructures incorporate various types of nailer strips. These nailer stirps may be connected to structural elements or form part of structural elements. The following structural elements are known: Hollow structural steel (HSS) beams: These beams are made from steel tubes that are filled with concrete. The steel provides the strength, and the concrete provides weight to the beam. HSS beams are often used in building construction because they are strong, durable, and fire-resistant.

[0009] Combination wood and steel beams: Wood beams are strong and lightweight, while steel beams are strong and durable. They can be used together to create a composite beam that is both strong and lightweight. This type of beam is often used in roof trusses and floor joists.

[0010] Combination steel and FRP beams and FRP and concrete: Fibre reinforced plastic (FRP) is a strong and lightweight material that is often used in composite beams. Steel beams can be used to provide the strength, while FRP beams can be used to provide the lightweight and corrosion-resistant properties. This type of beam is often used in bridges and other structures that require a high degree of strength and durability.

[0011] Combination wood and aluminium beams: Wood beams are strong and versatile, while aluminium beams are lightweight and corrosion-resistant. They can be used together to create a composite beam that is both strong and lightweight. This type of beam is often used in exterior applications, such as balconies and decks.

[0012] United states patent application number US2167835A entitled “Structural joist or nailer stud”, in the name of Gerald G Greulich (“Greulich”), describes a structural member comprising a solid web and an enlarged head portion at one end of said web, said enlarged head portion comprising a channel and a nailing strip positioned within said channel and extending above the channel sides, said nailing strip covered by a sheet metal member connected to the sides of said channel. This can be problematic as the nailing strip is covered by a sheet of metal to keep the nailer strip in place. This sheet metal will make it more difficult for nails to be nailed into the nailer strip. The use of a wood nailer strip is also a problem as wood can expand or contract due to the amount of moisture inside the wood. Wood may lead to a creaking sound which can be an annoyance, especially in flooring. If the wood is exposed to the elements, durability may be limited which could impact the structural integrity over time.

[0013] Combination foam and metal channels: foam is versatile and malleable, while metal channels provide strength and protection of the foam.

[0014] Chinese patent number CN114012964A entitled “REINFORCED KEEL, MANUFACTURING MOLD AND PREPARATION METHOD”, in the name of Anhui Sentai Wpc Technology Floor Co Ltd (“Sentai”), describes a reinforced keel comprising a keel main body and a foaming core layer arranged in the keel main body, wherein the keel main body comprises a bottom plate and two side plates which are symmetrically arranged on two sides of the bottom plate and are integrally formed with the bottom plate, and the foaming core layer is provided with an upper bearing surface; the invention provides a reinforced keel, which is convenient for a nailing process in a plate mounting process; the invention also provides a manufactured die which is simple and reasonable in design and good in production effect.

[0015] This could be quite problematic, as the keel profile described in Sentai features a complex profile, particularly its claw, which may be difficult and costly to replicate if fabricated from steel. The foaming agent may also fill the whole of the cavity formed in the keel and will be limited to the shape of the cavity.

[0016] OBJECT OF THE INVENTION

[0017] It is an object of this invention to provide a structural element which, at least partially, alleviates some of the above-mentioned difficulties.

[0018] SUMMARY OF THE INVENTION

[0019] In accordance with this invention there is provided a structural element comprising a body made from a first material defining a structural channel which has a retaining formation; a complementary shaped inset made of a material softer than the first material; wherein the inset is retained within the channel with the inset having a cavity between the inset and the channel.

[0020] The structural element wherein the retaining formation may be a lip.

[0021] The structural element wherein the structural channel may be a lipped channel.

[0022] The structural element wherein the inset may receive a fastener which fastens a board to the inset.

[0023] The structural element wherein the inset may be a nailer strip.

[0024] The structural element wherein the inset may have a U-shape.

[0025] The structural element wherein the inset may have an inverted U-shape.

[0026] The structural element wherein the inset may have a T-shape.

[0027] The structural element wherein the inset may have an l-shape.

[0028] The structural element wherein the inset may have an internal hollow.

[0029] The structural element wherein the first material may be steel, aluminium, metal, an alloy, fibre reinforced polymer or any other appropriate material such as a composite material, the invention is not limited in this regard.

[0030] The structural element wherein the second material may be a composite, plastics material, or any other appropriate material, the invention is not limited in this regard. The structural element wherein the inset may be an extruded wood plastic composite or similar extruded inset.

[0031] The structural element wherein the fastener may be a screw, nail, or similar retaining means.

[0032] The structural element wherein the board may be a fence panel, cladding or any other building element.

[0033] The structural element wherein the board may be a wooden board such as a ceder board, or a composite or be manufactured out of any other plastics, recycled material, fibre cement or stone cladding.

[0034] The structural element wherein the board may be attached directly to the inset by means of the fastener.

[0035] The structural element wherein the structural element may be formed by a metal rolling process.

[0036] The structural element wherein the inset may be formed by an extrusion process.

[0037] The structural element wherein the inset may be a foam or similar material.

[0038] The structural element wherein the structural channel and the inset may be formed substantially simultaneously.

[0039] The structural element wherein the inset may be guided lengthwise into the structural channel.

[0040] The structural element wherein a third material, which is softer than the second material, may be associated to the inset and located outside of the channel. The structural element wherein a third material, which is softer than the second material, may be associated with the inset and located inside of the channel.

[0041] The invention further provides for a structural element comprising a body made from a first material defining a structural channel which has a retaining formation; a complementary shaped inset made of a material softer than the first material; wherein the inset is retained within the channel with the inset having a hollow which runs at least part of the length of the inset.

[0042] These and other features of the invention are described in more detail below.

[0043] BRIEF DESCRIPTION OF THE DRAWINGS

[0044] One embodiment of the invention is described below, by way of example only, with reference to the drawings in which:

[0045] Figure 1 shows a structural element;

[0046] Figure 2 shows an end view of the structural element of figure 1 ;

[0047] Figure 3 shows the structural element of figure 1 as part of a fence;

[0048] Figure 4 shows a detailed view of the structural element of figure

[0049] 3;

[0050] Figure 5 shows a detailed end view of the structural element of figure 3; and

[0051] Figure 6 shows the structural element of figure 1 as part of a fence; DETAILED DESCRIPTION OF THE DRAWINGS

[0052] The following detailed description is presented to enable any person skilled in the art to make and use the invention. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the invention. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. The present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein

[0053] With reference to the drawings, a structural element is generally depicted by reference numeral 1 .

[0054] The structural element 1 comprises a body which is made from a first material and its shape resembles a structural channel 2 or a lipped channel which has a retaining formation 4;

[0055] A complementary shaped inset 5 which is retained within the structural channel 2 by the retaining formations 4.

[0056] The inset 5 is made from a material which is softer than the material of which the structural channel 2 is made.

[0057] A cavity 3 in the inset 5 is found between the inset 5 and an inner wall of the structural channel 2. This cavity 3 specifically forms part of the inset to lessen the amount of material used and consequently reducing the weight of the structural element 1 . The retaining formation 4 has a lipped shape and the structural channel 2 is essentially a lipped channel.

[0058] In use the structural element 1 will be used to support boards 6 in place. In this embodiment the board 6 is a fence panel 6, which forms part of any number of fence panels 6.

[0059] The fence panel 6 is attached to the inset 5 by means of a fastener 7. In this embodiment the fastener is a nail 7.

[0060] The nail 7 is driven through the fence panel 6 into the inset 5. The inset 5 thus acts as a nailer strip 5. The fence panel / board 6 will be connected directly to, and supported by the nailer strip 5.

[0061] The combination of structural channel 2 and nailer strip 5 can provide an optimal balance between strength and weight requirements in that the structural channel 2 supports the nailer strip 5. The strength of the structural channel 2 comes from the material which it is made of in combination of its structure. In this embodiment the structural channel 2 is made from a lightweight metal material, such as aluminium. The channel is formed by extruding the material into its preferred shape.

[0062] The inset / nailer strip 5 is made from a second, softer material such as a composite. In this embodiment a wood plastic composite (“WPC”) is used. The inset is manufactured by an extrusion process.

[0063] In this embodiment, the structural channel, in turn, is supported by any number appropriate posts or supports such as fence posts 8.

[0064] In this embodiment the inset 5 has an ‘inverted’ U-shape. This is to allow for a large amount of surface contact with the inside walls of the structural channel 2 while still providing for a cavity 3 to lessen the weight of the structural element 1 . It also allows for effective load transfer. The U-shape fits and follows the structural channel 2 well to transfer loads effectively but removes as much unnecessary material to be as light-weight and cost-effective as possible. The structural element 1 is sized to resist specific load so the inset 5 has to match this geometry to a degree. The outer face of the inset 5 that takes nail 7 has to be a specific thickness to provide suitable withdrawal strength whilst not limiting installation.

[0065] The inverted U shape allows for a large portion of nailer strip 5.

[0066] The structural channel 2 and the inset 5 may be formed substantially simultaneously or the inset 5 is guided lengthwise into the structural channel 2.

[0067] The invention is not limited to the above described embodiment and many other embodiments are possible without departing from the scope of the invention. For instance, the inset 5 may have any appropriate shape, such as a T-shape, an l-shape or even have an internal hollow.

[0068] The first material may be a metal, an alloy, or any other appropriate material, the invention is not limited in this regard. The second material may be plastics material, or any other appropriate material, such as a foam, the invention is also not limited in this regard. The board may be a fence panel, cladding or any other building element. The board may be a wooden board such as a ceder board, or a composite or be manufactured out of any other plastics recycled material, fibre cement or stone cladding or any other building material.

[0069] The structural element may be used substantially horizontally and the board may be a floorboard. The use of the second, softer material, assists in noise reduction when pressure is applied to the top of the board. Over time, foot traffic can cause creaking noises when the board moves against a hard underlying structure, such as a metal beam. The use of the softer material to engage with the board assists in the acoustic properties of the floor and / or any other system that the structural element may form part of.

[0070] The fastener is not limited to being a nail and may be a screw, a staple, a bolt, or any other similar and / or appropriate retaining means. The invention further provides for a structural element comprising a body 1 made from a first material defining a structural channel 2 which has a retaining formation 4. A complementary shaped inset 5 made of a material softer than the first material. The inset 5 is retained within the channel 2 with the inset 5 having an internal hollow which runs at least part of the length of the inset 5.

[0071] The invention further provides a third material, which is softer than the second material, is associated to the inset and located either inside or outside of the channel. This, even softer material, may add to the acoustic properties of the invention.

[0072] The incorporation of a multi-material structural element offers numerous engineering, installation and practical advantages, particularly in construction applications where strength, weight reduction, and ease of installation are critical considerations. The unique combination of materials — such as a metal structural channel with a composite inset — provides a hybrid solution that balances structural integrity with user-friendly, durable and aesthetically pleasing assembly methods.

[0073] A crucial feature of this invention is the optimized interface between the structural channel 2 and the inset 5 as well as the interface between the inset 5 and the board / fence panel 6. The retaining formation 4 is designed to provide a secure and stable fit while allowing for minor tolerances in the manufacturing process. By ensuring a snug fit, the inset 5 remains securely positioned within the channel 2, preventing unwanted movement or displacement due to mechanical loads, vibrations, or environmental factors such as thermal expansion and contraction but also can prevent moisture ingress improving the longevity / durability of the system.

[0074] Further refinement of the inset 5 can include variations in surface texture or geometric modifications to enhance mechanical bonding between the materials. For instance, surface grooves, ridges, or micro-indentations can be incorporated along the inset’s exterior surfaces to increase frictional resistance within the structural channel 2. This enhances the overall structural integrity, particularly when subjected to repetitive loads, such as wind forces on a fence panel or foot traffic on a floorboard.

[0075] Additionally, the extrusion process used for the manufacture of the inset 5 allows for precise control over material composition and internal structure. The cavity 3 within the inset 5 is engineered not only to reduce weight and provide adequate withdrawal strength but may also improve flexibility and / or biassing properties. Depending on application requirements, this cavity can be filled with a resilient polymer or foam to enhance vibration and / or energy absorption and further contribute to noise reduction, making the structural element ideal for acoustic-sensitive applications such as residential and commercial flooring systems. The cavity can also be used to hide or house services. It can reduce thermal bridging and improve insulation.

[0076] The addition of a third, softer material associated with the inset 5 introduces a novel enhancement to the system’s performance. This tertiary layer can be strategically positioned and sized at critical contact points where additional insulation or energy absorption is required. For example, a foamed, rubberized or elastic coating on the exterior of the inset 5 can serve as an interface between the board 6 and the nailer strip 5, further mitigating noise, thermal, impact loads, fatigue and creep failures, and resulting in extending the lifespan of fasteners, fixtures, interactions between components and the system as a whole.

[0077] Moreover, the modular nature of the structural element 1 enables efficient scalability in construction applications. Variations in channel dimensions, inset thickness, and material composition can be tailored to specific structural demands, providing a customisable solution for different environmental conditions, drainage, and load-bearing requirements. The integration of preformed connection points or pilot holes within the structural channel 2 can facilitate rapid assembly, minimizing installation time and labour costs. In applications where the structural element is exposed to harsh environmental conditions, such as outdoor fencing or decking, protective coatings or treatments and additives can be applied to either the structural channel 2 and inset 5. Corrosion-resistant finishes, weather resistant finishes, additives, UV protection finishes, or moisture-resistant sealants enhance durability and longevity, ensuring that the system maintains its performance characteristics over extended periods.

[0078] Furthermore, the composite nature of the inset 5 allows for sustainability considerations, as recycled or natural materials can be incorporated into its formulation and the material required is reduced. The use of a wood-plastic composite (WPC), recycled or similar materials not only reduces environmental impact but also provides resistance to rotting, decay, insect damage, and warping — common issues in traditional wood nailer strips when not treated regularly. A fundamental flaw of wood based systems is that one cannot treat the whole of the interface between interlinking parts.

[0079] Overall, the invention presents a significant advancement in structural component design, effectively addressing challenges associated with material compatibility, load distribution, ease of installation, and long-term performance.

[0080] Through strategic engineering, research and development, and material selection, this hybrid structural element sets a new standard for cost-effective and efficient construction methodologies.

[0081] It is envisaged that incorporating the concept described herein to form part of all new nailer strips, fence posts or any other appropriate building. Employing a softer material as a nailing strip allows for efficient installation of other parts to the system when using high impact methods such as a nail gun. Using a method such as this directly into steel or aluminium or similar would typically be difficult or slow due to the properties of these types of materials. The combination of the two materials allows the structural material to be more effectively allocated to where it is needed - far behind the neutral axis, and the softer material more suitable for receiving high impact loads to where it’s needed - in the front. To effectively facilitate this, the steel (or similar material) and WPC (or similar material) geometries need to be in such a way as to provide a robust interaction between the two components. As a result, the combination of the two materials in their geometries allows for a cost-effective solution to this and similar types of applications. Where a third, even softer material, is added between the structural element and an item to be fixed to the structural element

Claims

CLAIMS1 . A structural element comprising a body made from a first material defining a structural channel which has a retaining formation; a complementary shaped inset made of a material softer than the first material; wherein the inset is retained within the channel with the inset having a cavity between the inset and the channel.

2. The structural element as claimed in claim 1 wherein the retaining formation is a lip.

3. The structural element as claimed in any of the preceding claims wherein the structural channel is a lipped channel.

4. The structural element as claimed in any of the preceding claims wherein the inset may receive a fastener which fastens a board to the inset.

5. The structural element as claimed in any of the preceding claims wherein the inset is a nailer strip.

6. The structural element as claimed in any of the preceding claims wherein the inset may have a II- shape.

7. The structural element of any one of claim 1 to claim 5 wherein the inset may have an inverted U-shape.

8. The structural element of any one of claim 1 to claim 5 wherein the inset may have a T-shape.

9. The structural element of any one of claim 1 to claim 5 wherein the inset may have an l-shape.

10. The structural element as claimed in any of the preceding claims wherein the inset may have an internal hollow.1 1 . The structural element as claimed in any of the preceding claims wherein the first material is any one or more of the following list: steel, aluminium, metal, an alloy, fibre reinforced polymer, a composite material.

12. The structural element as claimed in any of the preceding claims wherein the second material is any one or more of the following list: a composite, plastics material.

13. The structural element as claimed in any of the preceding claims wherein the inset is an extruded wood plastic composite or similar extruded inset.

14. The structural as claimed in any of the preceding claims element wherein the fastener is a screw, nail, or similar retaining means.

15. The structural element as claimed in any of the preceding claims wherein the board is a fence panel.

16. The structural element as claimed in any of claims 1 to 14 wherein the board is cladding.

17. The structural element as claimed in any of claims 1 to 14 wherein the board is another building element.

18. The structural element as claimed in any of the preceding claims wherein the board is a wooden board19. as claimed in any of the preceding claims wherein the board is any one or more of the following list: a ceder board, a composite or a boardmanufactured out of any other plastics recycled material, fibre cement or stone cladding.

20. The structural element as claimed in any of the preceding claims wherein the board is attached directly to the inset by means of the fastener.21 . The structural element as claimed in any of the preceding claims wherein the structural element is formed by a metal rolling process.

22. The structural element as claimed in any of the preceding claims wherein the inset is formed by an extrusion process.

23. The structural element as claimed in any of the preceding claims wherein the inset is a foam or similar material.

24. The structural element as claimed in any of the preceding claims wherein the structural channel and the inset is formed substantially simultaneously.

25. The structural element as claimed in any of the preceding claims wherein the inset is guided lengthwise into the structural channel.

26. The structural element as claimed in any of the preceding claims wherein a third material, which is softer than the second material, is associated to the inset and located outside of the channel.

27. The structural element as claimed in any of the preceding claims wherein a third material, which is softer than the second material, is associated with the inset and located inside of the channel.

28. The invention further provides for a structural element comprising a body made from a first material defining a structural channel which has a retaining formation;a complementary shaped inset made of a material softer than the first material; wherein the inset is retained within the channel with the inset having a hollow which runs at least part of the length of the inset.

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