Abstract The structures of the present invention start with a basic hollow tube of any desired outer shape and made of paper, plastic or metal. When paper is used, it is vacuum impregnated with a plastic resin and oven baked to give it rigidity. The tube may also be covered with an ornamental veneer, if desired. The tubes are provided with suitable openings to receive matching counterparts fitting against the openings. Strong, rigid core members of wood, plastic or metal are positioned in the tubular members with the abutting portions of the core members interconnected. The structure is placed in a clamp to hold the parts together in proper position. Polyurethane is then poured into one end, the end is capped, and the structure is rotated to evenly distribute the polyurethane. The urethane sets at room temperature and expands as it sets to internally mold the members into a solid structure. The finished structure can be drilled, machined, or bolted to add features in the conventional manner.
A free standing portable structure that is capable of supporting loads thereon, comprising a plurality of hollow tubular members that are interfitted to define a unitary construction, said members being formed of an oven baked resin impregnated paper, each of said members having a reinforcing core located therein that extends substantially the length thereof, the core of each member occupying less than the total volume therein to define an interior space therein, each member having portions of the core therein exposed at predetermined locations, the core of each member at an exposed location engaging an exposed core of an adjacent member for interengaging the members, a plurality of communicating channels being defined by the interior spaces of the members that are interengaged by the cores therein, and a polyurethane filler material extending throughout the interior of said members and occupying the spaces formed therein to positively interlock the members together in the unitary construction.
Claim 2
Dependent Claim
154 words
A free standing portable structure that is capable of supporting loads thereon, comprising a plurality of hollow tubular members that are interfitted to define a unitary construction, said members being formed of an oven baked resin impregnated paper, each of said members having a reinforcing core located therein that extends substantially the length thereof, the core of each member occupying less than the total volume therein to define an interior space therein, each member having portions of the core therein exposed at predetermined locations, the core of each member at an exposed location engaging an exposed core of an adjacent member for interengaging the members, a plurality of communicating channels being defined by the interior spaces of the members that are interengaged by the cores therein, and a polyurethane filler material extending throughout the interior of said members and occupying the spaces formed therein to positively interlock the members together in the unitary construction.
Claim 3
Dependent Claim
18 words
A structure as in claim 1, wherein said reinforcing cores comprise elongated wooden cores of rectangular cross section.
Claim 4
Dependent Claim
36 words
A structure as in claim 1, wherein said cores are joined by a tongue and groove arrangement, the tongue being formed on a first core and being received in a groove formed in a mating core.
Claim 5
Dependent Claim
17 words
A structure as in claim 1, wherein said hollow tubular members include exposed surfaces of ornamental veneer.