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US 12,766,773 B2Granted
Construction components and systems fabricated using extruded materials
AssigneeNot Wood Inc.
InventorsJordan Darling, Shane Louis Kenyon
Life of this patent
Estimating the term…
Abstract
Construction components and systems fabricated using extruded materials are disclosed. A particular embodiment includes: a sheet fabricated from an extruded material; and a core structure internal to the sheet, the core structure including voids, the voids being triangular-shaped and arranged in an alternately inverted pattern.
Claims12
A method for forming a sheet, the method comprising:
- extruding, through an extrusion die, a heated thermoplastic material to form the sheet,
- wherein the sheet comprises a first side, a second side, and a series of voids disposed between the first side and the second side,
- wherein each void in the series of voids comprises a triangular shape and is arranged in an alternatingly inverted pattern,
- wherein each vertex of the triangular shape is configured with a rounded corner, and
- wherein the sheet has a length in an x-direction, the x-direction being the direction of extrusion, a width in a y-direction, and a thickness in a z-direction;
- and
- injecting, into the extrusion die and during the extruding, a foam distinct from the thermoplastic material such that each void in the series of voids is at least partially filled with foam as the heated thermoplastic material exits the extrusion die.
4 more elements
A method for forming a sheet, the method comprising:
- extruding, through an extrusion die, a heated thermoplastic material to form the sheet,
- wherein the sheet comprises a first side, a second side, and a series of voids disposed between the first side and the second side,
- wherein each void in the series of voids comprises a triangular shape and is arranged in an alternatingly inverted pattern,
- wherein each vertex of the triangular shape is configured with a rounded corner,
- wherein the sheet has a length in an x-direction, the x-direction being the direction of extrusion, a width in a y-direction, and a thickness in a z-direction, and
- wherein the thermoplastic material is monolithic throughout the sheet;
- forming a regular pattern of fastening slots extending along the sheet in the x-direction, wherein each fastening slot is positioned atop a corresponding triangular void to create a self-aligning guide that facilitates accurate fastener installation;
- and
- forming a series of raised anti-slip features extending along the sheet in the x-direction.
6 more elements
A method for forming a sheet, the method comprising:
- extruding, through an extrusion die, a heated thermoplastic material to form the sheet,
- wherein the sheet comprises a first side, a second side, and a series of voids disposed between the first side and the second side,
- wherein each void in the series of voids comprises a triangular shape and is arranged in an alternatingly inverted pattern,
- wherein each vertex of the triangular shape is configured with a rounded corner, and
- wherein the sheet has a length in an x-direction, the x-direction being the direction of extrusion, a width in a y-direction, and a thickness in a z-direction;
- inserting, through the extrusion die and during the extruding, electrical wiring such that the electrical wiring extends along one of the series of voids as the heated thermoplastic material exits the extrusion die.
3 more elements
A method for forming a sheet, the method comprising:
- extruding, through an extrusion die, a heated thermoplastic material to form the sheet, wherein the sheet comprises a first side, a second side, and a series of voids disposed between the first side and the second side;
- pressing the sheet in a first location and in a direction perpendicular to the direction of the extruding to close a first end of each void of the series of voids;
- pressurizing each void in the series of voids above ambient pressure;
- and
- pressing the sheet in a second location and in the direction perpendicular to the direction of the extruding to close a second end of each void of the series of voids to form a pressurized sheet.
2 more elements
Dependencies are inferred from the claim text.