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US5722589A Expired / Lapsed US ⏱️ 0.0 years remaining

Composite load bearing structure

Assignee: Green Track Inc
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Filing: 1997-03-10
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Granted: 1998-03-03
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Expires: 2017-03-10
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Abstract

Abstract A composite load bearing structure comprises a main body portion having a top surface and a bottom surface defining a dimension of thickness therebetween, first and second side surfaces defining a dimension of width therebetween, first and second end surfaces defining a dimension of length therebetween, and a first longitudinal axis oriented along the length of the main body portion. The thickness is significantly less than at least the length of the load bearing structure. The main body portion is made of a first composite material comprising a binding constituent in a proportion of about 10% to about 20% by volume, and an aggregate material in a proportion of about 80% to about 90% by volume. The binding constituent comprises polyethylene or a polyethylene blend having at least 10% polyethylene. The aggregate material is in the form of irregular multi-faceted pieces of crushed furnace slag, crushed gravel, crushed limestone, crushed granite, crushed basalt, crushed trap rock, and mixtures thereof, and the pieces of aggregate material are distributed and otherwise arranged within the main body portion so that opposed surfaces of the pieces of aggregate material have at least partial contact, one with another, in a contiguous manner. An inner strengthening member is disposed within the main body, and may comprise reinforcing bars; rolled, drawn, or cast ferrous sections; rolled, drawn, or cast composite alloy sections; plastic, metallic, and carbon based fibers; wire mesh, and expanded metal mesh.

Inventors

  • 👤 Denis C. Richards

Bibliographic Details

Application Number —
Jurisdiction US
Data Source google_patents
Last Synchronized 2026-11-04 00:18
CPC Classifications
E; E01; E01B; E01B3/00; E01B3/46; E01B3/28; E01B3/36

Claims Analysis

Total Claims: 24
Claim 1
Independent Claim 286 words
A composite load bearing structure comprising: a main body portion having a top surface and a bottom surface defining a dimension of thickness therebetween, first and second-side surfaces defining a dimension of width therebetween, first and second end surfaces defining a dimension of length therebetween, and a first longitudinal axis oriented along the length of said main body portion; wherein said dimension of thickness is significantly less than at least said length of said load bearing structure; wherein said main body portion is made of a first composite material comprising a binding constituent in a proportion of about 10% to about 20% by volume, and an aggregate material in a proportion of about 80% to about 90% by volume; wherein said binding constituent in said main body portion comprises a plastic material chosen from the group consisting of polyethylene and a polyethylene blend having at least 10% polyethylene; wherein said aggregate material is in the form of irregular multi-faceted pieces chosen from the group consisting of crushed furnace slag, crushed gravel, crushed limestone, crushed granite, crushed basalt, crushed trap rock, and mixtures thereof; and wherein the pieces of said aggregate material are distributed and otherwise arranged within said main body portion so that opposed surfaces of said pieces of aggregate material have at least partial contact, one with another, in a contiguous manner; and at least one inner strengthening member having a second longitudinal axis which is substantially parallel to said first longitudinal axis; wherein said at least one inner strengthening member is chosen from the group consisting of reinforcing bars; rolled, drawn, or cast ferrous sections; rolled, drawn, or cast composite alloy sections; plastic, metallic, and carbon based fibers; wire mesh, and expanded metal mesh.
Claim 2
Dependent Claim 286 words
A composite load bearing structure comprising: a main body portion having a top surface and a bottom surface defining a dimension of thickness therebetween, first and second-side surfaces defining a dimension of width therebetween, first and second end surfaces defining a dimension of length therebetween, and a first longitudinal axis oriented along the length of said main body portion; wherein said dimension of thickness is significantly less than at least said length of said load bearing structure; wherein said main body portion is made of a first composite material comprising a binding constituent in a proportion of about 10% to about 20% by volume, and an aggregate material in a proportion of about 80% to about 90% by volume; wherein said binding constituent in said main body portion comprises a plastic material chosen from the group consisting of polyethylene and a polyethylene blend having at least 10% polyethylene; wherein said aggregate material is in the form of irregular multi-faceted pieces chosen from the group consisting of crushed furnace slag, crushed gravel, crushed limestone, crushed granite, crushed basalt, crushed trap rock, and mixtures thereof; and wherein the pieces of said aggregate material are distributed and otherwise arranged within said main body portion so that opposed surfaces of said pieces of aggregate material have at least partial contact, one with another, in a contiguous manner; and at least one inner strengthening member having a second longitudinal axis which is substantially parallel to said first longitudinal axis; wherein said at least one inner strengthening member is chosen from the group consisting of reinforcing bars; rolled, drawn, or cast ferrous sections; rolled, drawn, or cast composite alloy sections; plastic, metallic, and carbon based fibers; wire mesh, and expanded metal mesh.
Claim 3
Dependent Claim 34 words
The composite load bearing structure of claim 1, wherein said composite load bearing structure comprises a railway tie and said at least on inner strengthening member is elongate and made from a metal material.
Claim 4
Dependent Claim 54 words
The composite load bearing structure of claim 2, wherein said at least one inner strengthening member is fully recessed in said main body portion so as to be completely covered by said first composite material such that said first composite material forms a substantially waterproof barrier around said at least one inner strengthening member.
Claim 5
Dependent Claim 23 words
The composite load bearing structure of claim 3, wherein said at least one inner strengthening member is made from a ferrous metal material.
Claim 6
Dependent Claim 32 words
The composite load bearing structure of claim 4, wherein said at least one inner strengthening member comprises a plurality of inner strengthening members that are structurally joined one to another by welding.
Claim 7
Dependent Claim 20 words
The composite load bearing structure of claim 5, wherein said at least one metal inner strengthening member comprises reinforcing bar.
Claim 8
Dependent Claim 52 words
The composite load bearing structure of claim 6, wherein said plurality of inner strengthening members comprises two elongate inner strengthening members adjacent the top surface of said main body portion and three elongate inner strengthening members adjacent the bottom surface of said main body portion, together disposed substantially in a "U"-shaped pattern.
Claim 9
Dependent Claim 28 words
The composite load bearing structure of claim 4, wherein said at least one metal inner strengthening member is chosen from the group of high-carbon steel and stainless steel.
Claim 10
Dependent Claim 34 words
The composite load bearing structure of claim 8, wherein said at least one metal inner strengthening member has a cross-section in the shape of one of a "I", "T", "U", "L", "C", and "H".
Claim 11
Dependent Claim 50 words
The composite load bearing structure of claim 2, wherein said main body portion has at least one fastener receiving aperture therein, and wherein each said at least one fastener receiving aperture is adapted to receive and retain a fastening member therein for fastening the rails of a railroad track thereto.
Claim 12
Dependent Claim 61 words
The composite load bearing structure of claim 10, wherein each said at least one fastener receiving aperture is disposed within a corresponding fastener receiving element, and each fastener receiving element is securely retained within said main body portion of said composite load bearing structure so as to dispose said fastener receiving aperture at the exterior of said composite load bearing structure.
Claim 13
Dependent Claim 59 words
The composite load bearing structure of claim 1, wherein said at least one inner strengthening member is made from a metal material fully recessed in said main body portion so as to be completely covered by said first composite material such that said first composite material forms a substantially waterproof barrier around said at least one inner strengthening member.
Claim 14
Dependent Claim 23 words
The composite load bearing structure of claim 12, wherein said at least one inner strengthening member is made from a ferrous metal material.
Claim 15
Dependent Claim 32 words
The composite load bearing structure of claim 13, wherein said at least one inner strengthening member comprises a plurality of inner strengthening members that are structurally joined one to another by welding.
Claim 16
Dependent Claim 25 words
The composite load bearing structure of claim 1, wherein said dimension of thickness is also significantly less than said width of said load bearing structure.
Claim 17
Dependent Claim 41 words
The composite load bearing structure of claim 1, wherein said load bearing structure is chosen from the group of load bearing structures consisting of landscaping structural members, sound barriers, traffic barriers, surfacing slabs, retaining wall members, fence posts, and preformed curbs.
Claim 18
Dependent Claim 25 words
The composite load bearing structure of claim 1, wherein said dimension of width is also significantly less than said length of said load bearing structure.
Claim 19
Dependent Claim 35 words
The composite load bearing structure of claim 1, wherein said plastic at least one inner strengthening member is reinforced with one of a glass fibre material, high strength monofilament fibre material and carbon based fiber.
Claim 20
Dependent Claim 22 words
The composite load bearing structure of claim 1, wherein said plastic material in said main body portion comprises substantially exclusively virgin polyethylene.
Claim 21
Dependent Claim 22 words
The composite load bearing structure of claim 1, wherein said plastic material in said main body portion comprises substantially exclusively recycled polyethylene.
Claim 22
Dependent Claim 98 words
The composite load bearing structure of claim 1, wherein said pieces of said aggregate material are distributed in size such that about 100% of said pieces are shaped and dimensioned so as to be passable through a 1.27 cm screen, about 30% of said pieces are shaped and dimensioned so as to be passable through a 0.93 cm screen, about 2.0% of said pieces are shaped and dimensioned so as to be passable through a 0.63 cm screen, and substantially none of said pieces are shaped and dimensioned so as to be passable through a 0.32 cm screen.
Claim 23
Dependent Claim 55 words
The composite load bearing structure of claim 1, wherein said main body portion comprises from about 99% to about 30% of the total volume of said composite load bearing structure, and said at least one inner strengthening member comprises from about 1% to about 30% of the total volume of said composite load bearing structure.
Claim 24
Dependent Claim 39 words
The composite load bearing structure of claim 1, further comprising strands of high tensile strength fibre material in a proportion of about 0% to about 10% by volume disposed throughout said first composite material of said main body portion.

References Cited (Backward Citations)

US1616266A Cited
US3813040A Cited
US4150790A Cited
US5104039A Cited
US5367007A Cited
US5609295A Cited

USPTO Annuity & Maintenance Windows

Annuity Stage Window Opens Payment Deadline Surcharge Period Until Estimated Fee Status
3.5 Years (Year 4) 2001-03-02 2001-09-01 2002-03-03 $2000.00 Window Closed / Lapsed
7.5 Years (Year 8) 2005-03-02 2005-09-01 2006-03-03 $3760.00 Window Closed / Lapsed
11.5 Years (Year 12) 2009-03-02 2009-09-01 2010-03-03 $7700.00 Window Closed / Lapsed

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