A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

Various hybrid structures and methods of making the hybrid structures are provided. In one embodiment, a hybrid structure includes a backbone member of a first material composition and a secondary member of a second material composition different than the backbone member. The backbone member includes at least one closed portion along the length of the backbone member having a cross-section which varies along the length of the backbone, and the secondary member is disposed about at least a portion of the backbone member. In another embodiment, the secondary member extends about a portion of the external surface of the backbone member, through an opening of the backbone member and to the interior of the backbone member to interlock with the backbone member.

Various hybrid structures and methods of making the hybrid structures are provided. In one embodiment, a hybrid structure includes a backbone member of a first material composition and a secondary member of a second material composition different than the backbone member. The backbone member includes at least one closed portion along the length of the backbone member having a cross-section which varies along the length of the backbone, and the secondary member is disposed about at least a portion of the backbone member. In another embodiment, the secondary member extends about a portion of the external surface of the backbone member, through an opening of the backbone member and to the interior of the backbone member to interlock with the backbone member.

A structural reinforced composite construction mat includes a plurality of composite plastic beams that are ganged together to define the mat, with a plurality of flitch plates disposed between at least some of the plastic beams to provide additional strength and rigidity to the mat. The plastic beams may be made of a composite material have a generally rectangular cross-section. The flitch plates have a width (vertical height) when disposed between adjacent beams that is less than the width (vertical height) of the beams, such that the flitch plates may be recessed below and above the top and bottom surfaces of the mat, respectively. A plurality of rods extend in the lateral direction through the beams and plates to compress the beams and plates against each. The flitch plates may be metal or fiber-reinforced resin and may further include slotted holes to allow the beams to retract lengthwise in response to environmental changes.

A structural reinforced composite construction mat includes a plurality of composite plastic beams that are ganged together to define the mat, with a plurality of flitch plates disposed between at least some of the plastic beams to provide additional strength and rigidity to the mat. The plastic beams may be made of a composite material have a generally rectangular cross-section. The flitch plates have a width (vertical height) when disposed between adjacent beams that is less than the width (vertical height) of the beams, such that the flitch plates may be recessed below and above the top and bottom surfaces of the mat, respectively. A plurality of rods extend in the lateral direction through the beams and plates to compress the beams and plates against each. The flitch plates may be metal or fiber-reinforced resin and may further include slotted holes to allow the beams to retract lengthwise in response to environmental changes.

A method of making a fiber reinforced hoop includes forming two plates having a face opposing one another and defining an outer periphery with a recessed groove to define a channel between the two plates. Fibrous strands coated with an adhesive are wrapped around the two plates within the channel a plurality of times. The adhesive is allowed to cure so that the fibrous strands form a rigid hoop. In a particular embodiment, the two plates are connected to a rotary spindle to rotate the two plates a plurality of times as the fibrous strands are fed into the channel. In a still further embodiment, multiple plate sets can be mounted to rotate with the spindle and fibrous strands can be wound into the channels in each of the plate sets so that multiple hoops can be formed and cured simultaneously.

A method of manufacturing a pre-stressed beam or panel and the resulting beam or panel are described. The method includes providing a timber-based component (1); providing a pre-stressing member (9) arranged along the timber-based component; applying a tensile force to the pre-stressing member (9); providing concrete anchors (11a, 11b) at locations that are spaced apart along the timber-based component (1); coupling the pre-stressing member (9) to the concrete anchors (11a, 11b); and releasing the tensile force on the pre-stressing member (9) to transfer a compressive force to the timber-based component (1) through the concrete anchors (11a, 11b) to form a pre-stressed beam or panel.

A method of manufacturing a pre-stressed beam or panel and the resulting beam or panel are described. The method includes providing a timber-based component (1); providing a pre-stressing member (9) arranged along the timber-based component; applying a tensile force to the pre-stressing member (9); providing concrete anchors (11a, 11b) at locations that are spaced apart along the timber-based component (1); coupling the pre-stressing member (9) to the concrete anchors (11a, 11b); and releasing the tensile force on the pre-stressing member (9) to transfer a compressive force to the timber-based component (1) through the concrete anchors (11a, 11b) to form a pre-stressed beam or panel.

The present invention is primarily directed to improvements of a support assembly having a versatile structure capable of use with a variety of different products, devices, etc. intended for outdoor and/or indoor use such as, but not limited to, furniture, and/or umbrella or shade structures. The support assembly includes a body, preferably having an elongated configuration and a plurality of connector structures fixedly connected in outwardly extending, collectively surrounding relation thereto. The plurality of connector structures movably and removably interconnect one or more inserts in overlying relation to an outer surface of the body and along a length thereof. When the body is structured to define a support pole for an umbrella assembly, the plurality of connectors extend outwardly from the one or more inserts in movable engagement with a canopy activating hub, thereby maintaining a spacing between the hub and the inserts, concurrent to travel of the hub along the length of the body.

A permanent form (13) serving to form concrete structures and comprising sidewalls (11) comprises: an interior form (14) that forms the inner face of a side wall; an exterior form (16) that forms the outer face of the sidewall; and a plurality of vertical reinforcements (17) that are disposed between the interior form and the exterior form and that hold the exterior form alone or together with the interior form. The exterior form and the interior form have: a plurality of base plates (18) that are formed from plastic into square plates and that are aligned so as to be in firm contact with each other in the vertical and horizontal directions; a plurality of central reinforcement plates (19) that are formed from plastic into square plates substantially equal in size to the base plates, that join four adjacent base plates, and that are aligned so as to be in firm contact with each other in the vertical and horizontal directions; and a plurality of end reinforcement plates (21) that are formed from plastic into rectangular plates are arranged into a quadrangular frame so as to join adjacent base plates while being located on the outer edges of the plurality of central reinforcement plates aligned so as to be in firm contact with each other in the vertical and horizontal directions.