| US 7,592,059 B2 | ||
| Lightweight, composite structural railroad ties | ||
| Kevin K. Lane, Fort Collins, Colo. (US); Dustin K. Lane, legal representative; Paul A. Carothers, 400 Cedar Hill La., Arcata, Calif. 95521-8909 (US); Ryan K. Lane, 5220 Boardwalk Dr., No. A14, Fort Collins, Colo. 80524 (US); and Ryan P. Faino, 451 Boardwalk Dr., #206, Ft. Collins, Colo. 80525 (US) | ||
| Filed on Aug. 15, 2006, as Appl. No. 11/504,394. | ||
| Claims priority of provisional application 60/708568, filed on Aug. 16, 2005. | ||
| Prior Publication US 2007/0040293 A1, Feb. 22, 2007 | ||
| Int. Cl. B32B 3/00 (2006.01) | ||
| U.S. Cl. 428—71 [428/68; 428/76; 428/131; 428/543; 428/319.1; 428/319.3; 428/319.7; 52/309.4; 52/309.8; 52/309.9] | 16 Claims |
| 16. A composite structural element comprising:
a hollow frame made from a rigid material, said hollow frame having an interior, and an exterior, said hollow frame further
comprising:
a single U-shaped section further comprising:
an open side;
a closed bottom surface;
a first arm; and
a second arm substantially parallel to the first arm, the first arm and second arm connected with and perpendicular to the
closed bottom surface; and
a top section positioned over the open side substantially parallel to the closed bottom surface and joined with the first
arm and the second arm;
a first flap which is an extended portion of a first end of one of the first arm, the second arm, and the closed bottom surface,
and bendably correspondingly connected with the first end of one of the first arm, the second arm, and the closed bottom surface,
the first flap bending into position to cover and seal the first end of the hollow frame;
a second flap which is an extended portion of a second end of one of the first arm, the second arm, and the closed bottom
surface, and bendably correspondingly connected with the second end of one of the first arm, the second arm, and the closed
bottom surface, the second flap bending into position to cover and seal the second end of the hollow frame;
at least one insertion block in the interior, the insertion block adapted to comprise a support of the hollow frame in at
least one part where pressure is to be applied;
a plank of wood positioned along the interior of the first arm and the second arm;
a plurality of apertures through the hollow frame and the planks of wood to allow injection of a polyurethane foam;
the polyurethane foam that reacts and becomes rigid in the interior and completely fills the interior of the hollow frame
apart from the at least one insertion block; and
a substantially uniform high-solid protective coating provided over the exterior of the hollow frame.
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