BRPI0804730A2 - manufacturing process of composite material bars, machine and bar obtained - Google Patents

Abstract

The present invention is a method of manufacturing composite material bars, machine bars and bars, specially fabricated for use in the reinforcement of reinforced concrete structures, in place of the usual steel bars. The present process of incomplete pultrusion and extrusion, where the bar (B) is formed tensed and with protrusions on the core, generates a bar (B) with good mechanical properties, improving the tensile strength of the structures. The bar (B) thus produced offers better adhesion conditions with the concrete, and does not corrode, whatever the environment of its use.

Description

MANUFACTURING MATERIAL BAR, MACHINE AND OBTAINED BAR MANUFACTURING PROCESS

The present invention relates to a process of fabricating composite, machine and reinforced bar bars, specially manufactured for use in reinforcing reinforced concrete structures, in place of the usual steel bars.

Invention History

It is known to man of the reinforced concrete structure technique where steel bars are used to structure concrete, reinforcing it, in order to give the structure tensile strength.

When using steel, care should be taken to prevent its oxidation, such as offering a minimal concrete overlay on the bar, which varies by location. The more aggressive the environmental conditions are, such as regions near the sea, the greater the concrete coverage to be used.

Despite this caution, in aggressive or corrosive environments, there is a 85% faster degradation of steel bars than in less aggressive locations. The concrete also breaks where the steel oxidizes, as it increases in volume, breaking the concrete, causing huge repair and maintenance expenditures of concrete works, in addition to significantly reducing the useful life of these works.

For this reason, around the 1980s, studies on the use of composite material bars instead of steel bars were started. They have been specially developed to withstand and last for a long time in high corrosion environments, giving a valid and effective solution to this serious problem.

They do not deteriorate or degrade the concrete, are not affected by chlorine ions, acids, or high alkalinity.

Composite material bars are made from Fiber ReinforcedPolymer (FRP). Reinforcements include Glass Fiber Reinforced Polymer (GFRP), Carbon Fiber Reinforced Polymer (CFRP), Aramid Fiber Reinforced Polymer (AFRP) or Basalt Fiber Reinforced Polymer (BFRP). ). The fibers are bathed in a heat-resistant polymeric binder, which may be polyester, vinylester and / or epoxy resins, depending on their use and other types of binders.

These bars can be used anywhere, and advantageously where there is an aggressive steel environment.

Composite bars are able to eliminate corrosion problems caused by steel, and thereby considerably reduce maintenance and repair costs in: cold weather locations where large amounts of salt are used to thaw concrete on streets, bridges, roads. Its use is also suitable when aggregates mixed with cement to make concrete contain salt or other corrosive chemicals. These applications include: parking lots; coating of containers; Jersey balconies, railings; retaining walls; foundations; beams; floors and all works using contaminated aggregates.

Corrosion is a serious problem for reinforced concrete structures and is very common in: structures built in or near salt water, such as: harbor piers; retaining walls; dikes; coastal defense walls; partitions; floating structures; canals, roads and coastal buildings; platforms, swimming pools; aquariums; slabs and others; generally, of any concrete infrastructure that is situated within the saltwater operat.

In the chemical and animal processing industries, where there are all kinds of corrosive agents, as well as domestic or industrial wastewater, they also cause corrosion of steel. Typical applications for these cases are: slaughterhouses; wastewater treatment plants, petrochemical plants; pulp plants for paper; liquid gas plants; chemical plants; pipes; fossil fuel tanks; dams; cooling towers; chimneys; mineral installations such as refineries; nuclear power plants; nuclear-dumping concrete containers; etc.

It is very difficult, complex and costly to use steel bars to reinforce concrete in places where low electrical conductivity is required or where electromagnetic transparency is required, however this difficulty is overcome when using composite material bars. Some of the possible applications are: aluminum castings and copper; poles for the transport of electricity and communication by telephone. They can also be used in structures where they are installed: electronic equipment for telecommunications and air navigation; airport towers; airport floors, magnetic resonance imaging equipment in hospitals, railroad crossing; military structures with radar invisibility requirements; etc.

FRP bars are advantageously used as fortification anchor bolts, also known as Rockbolts with the advantage that in non-permanent works, one can drill or dig through them without damaging the drilling rig; also in tunnels or mines with acidic waters or very aggressive environments for the steel inside; in mines where the extracted mineral is contaminated by steel in its refining process.

The bars of composite material can be applied as a fortification also in: open cut mining walls; tunnels; pikes, slopes etc.

The use of composite material bars, whose density is low compared to steel (close to 25% of steel weight), is very convenient in reinforced concrete constructions where soils cannot withstand very heavy loads; remote geographical locations, sensitive environmental areas, and active seismic locations are examples of problematic places where the use of lightweight frames in concrete may solve the problem.

Particularly, in South American countries such as Chile, Peru and Brazil, composite material bars have been used to reinforce polymeric concrete in copper electro-sourcing cells in miners such as Chuquicamata, Enami, El Abra, Green Mantles, Escondida, Cerro Colorado, Chile; lio, Milpilla, Mantles of La Luna, Peru; Caraiba, in Brazil; also as reinforcements of prefabricated concrete beams for extension of drydock N ° 2 sheeting for industrial sheds of this gunner, ASMAR, in Talcahuano Chile.

These types of bars are also used in concretes installed in harsh environments in the United States, Canada, Belgium, Sweden, Japan, Germany, UK, China, India, Australia and others.

Advantageously, composite bars have high tensile strengths greater than steel; and high strength / weight ratio; low weight (one quarter than steel); It provides excellent reinforcement when weight is important on site, for example for precast concrete parts, and considerably reduces transport costs as it can move four times more in volume; do not corrode; These composite materials offer chemical protection and safe mechanical resistance across the Ph scale; do not conduct electricity; provide excellent electrical and thermal insulation; have excellent fatigue strength (CFRP, AFRP); behave very well in cyclically charged situations; have good impact resistance; withstand severe or unforeseen loads at specific points; are provided with magnetic transparency; unaffected by electromagnetic fields; excellent for use where there is magnetic resonance equipment, navigation and telecommunications; they are dimensionally stable to severe thermal variations; expansion / contraction is low, which is very important when confined within deconcrete environments that are subject to wide temperature variations; FRP bars are an economically viable alternative for solving the corrosion problem of steel reinforcement.

Despite all these advantages of using composite material bars instead of steel bars in reinforced concrete structures, such bars are not homogeneous, causing a restriction on their use.

It is therefore an object of the present invention to have a process and machine for making composite bars, which are homogeneous throughout their length, and which are provided with helical shoulders which provide excellent adhesion with the concrete.

Advantageously, the present process of production gives homogeneity and allows a mass production, totally eliminates the moisture that is established between the fibers, before being moistened with heat-resistant resins, so as not to affect the adhesion between the fibers and the resin that covers them.

The fiber strands of the bars are kept under tension at all times of production, which allows the fiber yarns to be substantially parallel to each other, and all the wires that make up the reinforcement of the bar are subjected to the same tension. This allows to obtain bars with better mechanical properties than bars manufactured by prior art processes, as well as ensuring structural homogeneity along the bar.

This process provides a constant and homogeneous thermostable reinforcement / resin percentage throughout the fabrication, preferably 75 to 80% reinforcement and 25 to 20% resin for GFRP, and 60 to 70% reinforcement and 30 to 40% resin for CFRP, AFRP and BFRP, which provides excellent and homogeneous tensile strength

The bar formed by the present process will comprise fiber reinforced heels, thus offering adhesion resistance between the bar and the very similar and even higher concretes than steel.

The bar comprises a cover made by an extrusion process which guarantees the total elimination of the external thermostable resin ring and a homogeneous application of thickness, preferably between 0.4 to 0.6 mm, including over the already reinforced shoulders, ensuring a perfect seal of the structural core of the edges. Bars, to protect structural fibers from moisture and aggressive agents, this cover is shock resistant as well.

The process ensures a homogeneous cure and complete bars whatever their diameter, as well as a post cure, thus obtaining the best mechanical and chemical properties of the resins.

Brief Description of the Illustrations

In order to facilitate the understanding of the present invention, schematic figures of a particular embodiment are presented, whose dimensions and proportions are not necessarily the actual ones, since the figures are merely intended to didactically present the various aspects of the invention, whose scope of protection is determined only by the scope of the appended claims.

The following figures are attached:

Figure 1 is a schematic view of the machine (1) of the present invention;

Figure 2 illustrates a schematic view of the machine (1) without the cover;

Figure 3 shows a perspective view of the drying system (2);

Figure 4 shows a cross-sectional view of the drying chamber (21);

Figure 5 illustrates a perspective view of the meter (3);

Figure 6 illustrates an exploded view of the meter (3);

Figure 7 shows a side view of the pistons 411 and 412 moving the damper cylinders 312 and 313 respectively;

Figure 8 shows a perspective view of the directional or cold matrix (5);

Figure 9 illustrates a secondary moistened front view (7) and the spinner (6);

Figure 10 illustrates a dog-like perspective view (6);

Figure 11 shows a partial sectional view of the dispenser (8) Figure 12 shows a partial sectional view of the molder (9);

Figure 13 shows a perspective view of the tensioning system (10) with the armrests (12);

Figure 14 illustrates another perspective view of the tensioning system (10) with the armrests (12);

Fig. 15 shows a front view of the tensioning system (10) and the arm carriage (12) locked to a drag carriage (101);

Figure 16 shows a front view of the arm (121) being raised by the piston (125);

Figure 17 shows a front view of the arm (121) with the forceps (127) rotated horizontally by the piston (126);

Figure 18 illustrates a perspective view of the furnace (11);

Figure 19 illustrates a perspective view of a tractor or drag car (101);

Figure 20 shows a perspective view of the cylinder (112) of the furnace chamber (11).

Fig. 21 illustrates an enlarged view of detail A of Fig. 20;

Figure 22 shows a front view of the furnace (11) and the armrest carriage (121) catching a bar (B);

Figure 23 shows a front view of the arm carrier (121) positioning a bar (B) in the furnace (11);

Figure 24 shows a front view of the oven (11) and a hot air generator (117);

Figure 25 shows a side view of the bar (B);

Figure 26 illustrates a graph of the comparative stress / strain curves of steel bars, bars composed of graphite, carbon, aramid, glass and polyester fibers.

Description of the invention

In a first aspect the present invention is a method of manufacturing beaded composite bars (B), more specifically fiber-reinforced composite bars, for use with reinforcing concretes and structures, comprising a joint process wherein the core (B2) and the rib reinforcements (BI) of composite material are formed in a similar but not the same process as pultrusion, called the incomplete pultrusion variant while the overlays on the core (B2) and bumps (BI) are extruded. .

The present case comprises the steps of:

(a) bundling of yarns (f) of fibers oriented parallel to one another;

b) Applying voltage to bundled wires (f);

c) Bath of the wires (f) grouped in thermostable resins, kept tensioned;

d) Elimination of excess of thermostable resins by pressure, and regulation of the ratio (%) between resin and asfibres;

e) Forming the core (B2) of the bar (B) by means of a cold die (5);

(f) application of a helical resinstermostible fiber cord over the core (B2) with the reinforcement of the shoulders (BI);

g) Initiation of the polymerization process of the thermostable core (B2) and shoulders (BI) heat-resistant resin in a linear microwave oven (14);

(h) application of a thermosetting resin cover at room temperature around the core (B2) and the rib reinforcements (BI); (i) bar modeling (B);

j) Initiation of the polymerization process of the heat-resistant resin of the applied coating in a microwave-linear oven (14);

(k) polymerization of the thermostable core (B2) with bias (BI) resin, still stressed, and of the cover at a controlled temperature;

1) Post-curing the bars (b) by heating for about one hour at or above the glass-transfer temperature (tg) of the thermostable bar resin (B);

m) Cut bars (B) to desired dimensions.

The present process provides an eposterior bathing in thermostable resins, fiber filaments such as glass, carbon, aramid and / or basalt, which are formed by very thin (f) strands of these fibers, straight and oriented parallel to each other to get the best mechanical properties of the material.

This linear process makes it possible to obtain continuous reinforced composite materials, since the excess of thermostable and orderly resins is removed from the fibers, parallel to each other, and directed to a heat-stable resin bath, which contains catalysts, accelerators and other additives, always maintaining the tensioned fibers.

The next step is the preforming of the core (B2) of composite material, in which the excess deresin of the fibers is eliminated and the percent fiber / resin or reinforcement / thermostable resin is controlled, preferably in the proportion of 50 to 80%. fiber and 20% to 50% resin, similar to the pultrusion process.

Next, the core (B2) formed of eresin fiber, in definite percentages, enters a cold matrix or driver (5) to give it a cylindrical shape which, unlike prior art processes, in which hot matrices are used, the present process It does not need heat to conform the bar (B).

Upon leaving the cold matrix (5), by means of the process called incomplete pultrusion variant and without increasing the temperature of the matrix (5), the nucleus (B2) moves to place a resin-moistened fiber cord (c) that is arranged in a around the core (B2), serving as reinforcement of the shoulders (BI) (see figure 9). After that it goes to a linear microwave oven (14), where the polymerization of the resin of the core (B2) and the shoulders ( BI); then proceeding to a closed chamber (834) in the dispenser (8) (see figure 11). The closed chamber (834) is at the end of the extruder (8), where the core (B2) and the helical rib reinforcements (BI) are coated with thermostable resins added with thixotropic material, all at room temperature. Resettable resins attach to the core and bead helical reinforcements (BI) around their entire surface. Thixotropic resin cover (loaded resin), serves as chemical protection to core fiber reinforcements (B2) and shoulders (BI).

In the next step, with a swivel bracket or shaper (9), which shapes the bar (B), making the external finishing on the core (B2) and the shoulders (BI). These bumps (BI) give the bars (B) sufficient and necessary adhesion to the concrete according to the established standards.

After this step, the composite material core (B2) and its bead coating (BI) are joined together from the molder (9) and enter a second linear microwave oven (14) to initiate polymerization of the thixotropic deresin coating. traction system (10) pulls the tab (B) to carry out a continuous production process. Ready-made, always tensioned bar (B) enters a temperature controlled furnace (11) which accelerates and maximizes the polymerization process, so in this furnace (11), post curing is also a procedure to obtain the best mechanical properties. and resin chemicas. After curing is performed for one hour at temperatures equal to or above the daresin glass transition temperature (tg) used.

Once hardened and post-cured, the bars (B) are cut to the required extent, and after leaving the furnace (11) they are cooled.

Preferably, the present process comprises an initial step of drying the fiber strands (f) prior to their wetting with resin. It is carried out in a drying system (2) with a fan (22), a heater (23) and a drying chamber (21) that promotes moisture removal from the wires (f) (see Figures 3 and 4).

Pre-drying the yarns (f) is advantageous as it greatly improves the adhesion of the resin to the fibers and prevents any premature deterioration of the bar (B) by the presence of moisture.

In another aspect the present invention relates to a machine (1) for making fiber reinforced polymer (FRP) bars (B) having three basic parts: a bar forming part, a bar tensile part and a post-curing part.

In the first part of the machine (1) the deformation of the bar (B) begins. It is the place where the core (B2) of the bar (B) is formed by capturing the fibers in wires (f), forming a bundle of parallel wires (f), where a helical reinforcement for the shoulders (BI) is also added. and thermostable resin to protect the core (B2) and shoulder (BI) fibers; besides being where resin polymerization begins.

In the second part of the machine the gripper core (B2) is pulled by tractor or drag carts (101), mounted on a pair of chains (102), where the cars (101) are arranged at a distance of 12 meters from each other.

In the third part of the machine, curing is done, post-curing and drying of bar (B) in a post-curing furnace (11) for about an hour from the entry of bar (B) until its exit. from the furnace (11), where the bar (B) is kept in the rotational kiln at a speed of one revolution per hour. Also here the bars are cooled at the furnace outlet (11).

In more detail, it can be seen from the attached figures that the first part of the machine comprises a drying system (2) for removing moisture from the strands.

(f) the fibers. It is equipped with a turbine fan (22), a heater (23) and a drying chamber

(21) (see figures 3 and 4). Preferably these equipments are connected through stainless steel ducts, which thus do not deteriorate with the moisture extracted from the wires (f).

The fibers in yarns (f) first enter the drying chamber (21) which, with an open circuit, removes moisture from the yarns (f), for better adherence of liquid resin and especially to prevent deterioration of the bar (B) by any moisture. residual.

This system works with air absorbed from the environment by a turbine fan (22), which generates a draft in the system (2).

The air is heated by means of a heater (23) which generates a temperature of 75 to 90 ° C sufficient to dry the wires (f).

In the drying chamber (21) there is evaporation of moisture by the action of heat, which is dragged by the air stream, leaving the threads (f) dry. Said chamber (21) comprises a plurality of rollers (211) through which the threads (f) pass, to ensure their homogeneous drying.

Preferably, the drying chamber (21) comprises a temperature control system (25) responsible for controlling the internal temperature of the room where the set point programmed in the process is established. This system can also control the breather ( 24), it regulates the flow, everything being adjusted according to the speed of the process.

Moisture can be infrared controlled (not shown) and is preferably distance assessed and transmitted to a monitoring center by any known means.

After the wires (f) pass through the drying system (2), they are directed to a humidifier (3) with a resin tank (31), which self-supplies with catalyzed resin (see figures 5 and 6). The wires (f) pass through the tank (31), which contains a series of cylinders (311, 312 and 313), to direct the wires (f) into the tank (31) to impregnate them with resin. The amount of resin is measured by load cells (32) that record the weight.

The tank 31 is of any material suitable for resin reception so as not to react with it. It is supported by four uniformly distributed small load cells (32) which, according to weight, indicate the level of resin in the tank (31), which can determine the consumption per meter of wire (f), and activate the self-supply system. .

After the wires (f) pass through the tank (31), they go to presses for the removal of excess deresin. Such presses are present in the form of two cylinders 313 and 311 which are approximated to each other, limiting the space for the passage of the impregnated wires (f), thus removing excess resin.

The tank (31) comprises a housing (33) (Figure 6) to which two pistons (411 and 412) are fixed through an inverted "ü" structure (42). Pistons 411 and 412 move the upper cylinders 312 and 313 vertically, respectively, to bring them closer or further away from the lower cylinders 311 (see figures 5, 6 and 7).

The upper part (331) of the housing (33) is provided with hinges (330) which enable it to be pivoted with respect to the base (332), allowing for possible dotanque displacements (31) when necessary. All of this carcass (33) is anchored to the machine to allow its longitudinal displacement, preferably by means of long holes (not shown), commonly referred to as "dechinese eyes", which allows carcass (33) to have movement, which serves so that load cells (32) based on weight information assess the stress required to keep the core strands tensioned by numerically determining the stress required to act on the core and rod strands (B) as a function of weight.

The piston (411) moves (see figure 7) by vertically displacing the upper cylinder (312) which is supported by the sides of the frame (42) by rolling (not shown) until it encounters the lower cylinder (311), which only rotates around itself, and also about bearings. These two cylinders (311) and (312) are designed to compress and give the necessary tension to the wires (f) when forming the bar (B).

Said piston (412) (see figure 7), moving cylinder (313) towards cylinder (311), regulating the passage of resin impregnated wires (f), and thus their resin quantity, according to a pre-established percentage, by a system similar to that described in the previous paragraph. The amount of resin that adheres to the threads (f) is weighed and monitored by an electronic scale that constantly reports weight to obtain resin consumption per hour or fraction thereof.

The machine further comprises a cold die or taper (5) (see figure 8) used to direct the wires (f) and form the core (B2) of the bar (B) by forcing the wires (f) to join and form the first stage that corresponds to the core formation of the bar (B).

To form the helical shoulder (BI) of the bar (B), the machine comprises a spinner (6) (see figures 9 and 10) that rotates at the speed determined by the operator as the core (B2) of the bar (B) center of the spinner (6) according to the type of bar (B) to be obtained. This is done by rotating and advancing the core (B2) of the bar, obtaining the desired helical pitch.

The spinner (6) comprises a support shaft (61) of the entire movable assembly which is drilled through a diameter hole equivalent to the largest diameter of the bar core (B). The shaft (61) is mounted on a bearing assembly (62) and these in turn on bearing carriers (64) according to desired type and shape.

To the shaft (61) is coupled a gear (63) of diameter and number of teeth, which is determined by the gear ratio of the desired movable assembly.

A gearmotor (65) generates the movement according to the desired helical pitch (BI). The power output and speed of the gearmotor (65) is regulated by the pinion (66) that connects the gear (63) of the shaft (61) with the diameter and number of teeth determined in the gear ratio.

In order to make it possible to vary the speed and change the helical steps, the gearmotor (65) has a speed controller that increases or decreases its revolutions.

The machine (1) comprises a twist (75) which has the function of twisting a fiber strand to form a fiber strand (c), base of the helical rib (BI).

Through the hole of the shaft (61) of the spinner (6) passes the core (B2) of the bar (B); while the deforming strand (c) of the reinforcement (BI) passes through a secondary humidifier (7) where it is moistened with resin after being twisted in a twist (75) until it forms a fiber strand (c) which surrounds the core (B2), in helical form.

The core (B2) passes through the dog center (6) and the bead (c) is applied over it through the opening (67) to form the reinforcement (BI). The feedrate and core rotation (B2) are set according to the desired helical reinforcement pitch (BI).

As specified in the constructor structural calculation, the bar diameter (B), the heights of the reinforcements (Bl), its inclination angle and pitch, or the distance between the reinforcements (Bl) are defined.

The secondary humidifier (7) is formed by a resin tank (71) for wetting the fiberglass (f) base of the helical shoulder reinforcement (BI) on the core (B2). This secondary humidifier (7) comprises cylinders (72, 73 and 74) that direct the bead (c) deflects into the tank (71), moistening it, and oscillators (73) and (74) remove excess resin in the passage of the cord (c) between them.

The machine (1) comprises a microwave linear furnace (14) through which the core (B2) passes with the resin-moistened cord in order to initiate the polymerization process of the resin in the core and the fiberglass bead around the core. (B2). Preferably, a linear microwave oven (14) is used which allows homogeneous polymerization of the resin to be initiated, especially in bars of large diameters.

The machine (1) also comprises a feeder (8) (see Figure 11) which adds to the core (B2) and to the shoulder reinforcements (BI) a heat-resistant resin cover added with catalyst-prepared thixotropic material forming a cylindrical bar (B ) still in shape.

The doser (8) comprises a shaft (81) coupled to an endless screw forming a movable part. The endless shaft assembly has a hole that allows the bar core (B) to pass through. The shaft (81) is mounted on a set of bearings and these in turn on portholes (811).

To the shaft (81) is coupled a gear (82) of diameter and number of teeth, according to the desired advance.

The endless shaft (81) is the prepared deresin distributor mechanism, which adds the amount of matter needed to form the bar (B).

The helical path (812), plus the revolution of the rotation, displaces the resin and pushes it to the cylinder (831) followed by the cone (832) of the dispenser (8), which decreases its diameter to a cylinder (833) of the same diameter as the bar (B). This cylindrical part (833) may be altered according to the desired bar diameter (B).

The gear motor (not shown) generates the movement so that the passage of the endless shaft (81) moves the resin and compresses between the cylindrical distributing end (833) and the core (B2). Each revolution of the endless shaft (81) injects a predefined mixing volume around the bar core (B). Synchronization is established so that the dosing is in accordance with the production speed. The power and speed of the gearmotor is transmitted to a pinion (not shown) that connects to the worm gear (82), the diameter and number of teeth being determined according to the transmission. To enable rotation speed variation and change the dosage of the core mix (B2), the gearmotor comprises a speed controller that increases or decreases its revolutions.

The feeder (8) further comprises a feeder (85) that continuously supplies raw material, generating the pressure required to operate normally. The feeder 85 is provided with a mechanism for removing the unwanted material that is introduced into the process. It comprises a motor (851) that rotates an endless screw (852), carrying raw material to the feeder (8).

The speed of the feeder (85) is controlled by a speed controller (not shown) which allows the rotation of the motor (851) to be fed by feeding the feeder (8) as required in production. The endless screw (852) is coupled to an axle, formed into a movable single piece. To couple the motor shaft (851) to the endless screw shaft (852) there is a coupling (853), preferably rubber with brackets. iron, which allows the starter torques to be

The screw / auger assembly (812) has a hole in the middle for the bar (B) to pass through it. The shaft is mounted on a bearing assembly and these in turn on bearing holders (811).

A molder (9) (see figure 12) rotates around the core (B2) of the bar (BI) to form it. It rotates at the same speed and direction as the spinner (6), shaping the helical pitch over the spiral pitch made by its motor (not shown).

The molder (9) comprises shaping discs (91) that exert pressure on the bar (B), generating a uniform distribution of the material. The shape of the model disks 91 varies according to the type of bar (B) to be manufactured.

A shaft (92) engages the shaping mechanism, forming a single moving part. The shaft (92) carries in its interior the mold of the bar which, while rotating, retouching and adopting the characteristics of a screw, finishing the finishing of the bar (B). The shaft (92) is mounted on a set of bearings and these, in turn, on frame holders (93).

The shaft 92 is coupled to a gear having a certain diameter and number of teeth according to the desired feedrate.

The gearmotor generates the movement of the molder (9) synchronized with the pitch of the spinner (6), these two systems work at the same speed. The gearmotor gear has its diameter and number of teeth determined in the gear ratio. To vary the speed of rotation and synchronization, a speed controller is incorporated into the engine that increases or decreases its revolutions.

The machine comprises a second linear microwave oven (14) through which the core (B2) passes with the resin-dampened cord, and with the already molded resin thixotropic cover, the purpose of this furnace is to begin the process of polymerization of thixotropic resin which it is around the core (B2) and over the fiber strand around the core that makes the reinforcement of the shoulders (BI) in helical form. Microwave oven is preferred because it allows homogeneously initiating polymerization of resin with agentetixotropic resin, especially in large diameter bars.

In the second part of the machine the bar (B) already resins is kept tensioned by a traction system (10) with three tractors or drag (101), 12 meters apart, and two cars (101) pull one bar length (B) between them, equivalent to a bar unit (B) of approximately 12 meters. The system is driven by double chains (102) of 36 meters each, mated to the drive system by crowns (103) of about 0.822 meters in diameter.

The traction system (10) comprised of tractor cars (101) attached to the chains (102) by means of guides and crowns (103) is supported by a double T-steel profile structure (105) anchored to the floor.

Chains (102) are pulled by the bearings, bearing carrier brackets and gearbox from the sprocket axles (104).

A gear reducer (not shown) for the tensioner (10) sets the production speed of the machine (1), managing it directly; synchronously with the entire assembly. The gearmotor gear has the diameter and number of teeth set according to the transmission.

To change the production speed of the machine (1), a speed controller (not shown) is incorporated, which increases or decreases the speed of the tiller motor (10).

The chains (102) are held taut between the crowns (103) and supported by the frame (105) (see figures 13 and 14). They have guides (105), among ascoroas (103). Thus the system comprises two chain sets (102) and four guides (not shown) in the cars (101), which, in parallel and consecutively, operate at the same pace by dragging the three trolleys (101) of the traction system (10).

The drag carriage (101) is the traction mechanism of the machine (1), which moves between the crowns (103), which drive the chains (102) of the system. The grabbing operation of the bar (B) by the carriage (101) is done by gags (106). The compression activation of the bar (B) has the function of locking it in the upper transverse carriage (101) of the gauge (106); This mechanism operates over 12.1 meters while the bar (B) is being manufactured. After reaching the specified length, the bar (B) is taken up by mechanical and pneumatic arms (121), always maintaining the tension in the bars (B), which is then cut off from the axis of the bar-making machine (I). , to be taken to the oven (II), already in the third part of the machine.

The armrests (12) (see figures 13 and 14) are two and are arranged at the ends of the frame (105) of the traction system (10). Four guides (128) per carriage (12) are installed, moving at the same speed set for production and coupled to the drag carriage (101) for cutting the bar (B).

The coupling of the arm carriage (12) to the drag carriage (101) is made by a pneumatic piston (122), which is perpendicular to the arm carriage (12), and which is driven by a sensor (not shown), coupled to it. without an exact position. Once the bar (B) has been cut, the pneumatic pistons (122) are released, decoupling the two carriage (12) from the dragline (101). Then the two pistons (125) which are installed on one end of the arm carriage (12) are operated to bring the bar (B) to the furnace (11).

Once the boom (B) of the mechanical arms is released, the pistons (125) return the arm carriage (12) to its starting point.

The mechanical arms (121) are the transfer mechanisms that depart from the traction system (10) going to the furnace (11). Its mechanism is pneumatic and has four pistons, being a piston (123) which activates a clamping forceps (127) of the bar (B); a piston (125) which raises the arm (121) with the bar (B) (see figure 16), taking it from the production shaft; the third piston (126) rotates the caliper (127) from a vertical position to a horizontal position (see figure 17), directing it to position the bar (B) in the furnace (11), and the fourth piston (124) approaches end of the bar (B) in the oven (11). All operation of the arm (121) is done without stopping the traction system (10) to avoid cuts or intermittent manufacturing which generate quality problems in the finished product. The mechanical arms (121) are supported on the armrests (12) with supports, positioned at the ends of each arm, ensuring their operating effectiveness.

The machine (1) further comprises a bar cutting system (129) (B) in the form of a small tool (see Figure 16) mounted on one of the bar supporting arms (121), which cuts the bar (B) to the specified extent. . Said cutting tool (129) has a high hardness disk that rotates at high speed.

Preferably, this tool is operated automatically and its mechanism is pneumatic.

The third part of the machine is the furnace 11, as shown in Figure 18, has a cylindrical shape and comprises a concentric disc 111 which rotates the barrel axis 112 of the furnace inner chamber 11 which is supported by bars. (113). The housing (110) is fixed and supported on the floor independently of the disc (111). The housing (110) comprises six fan mixers (114) that homogenize the oven temperature (11), which is monitored by sensors (not shown), which by electronic means maintain the constant temperature required for post curing the material.

Preferably, the heating system is made by hot air generators 117 (see figure 24).

Hot air inlet or outlet is controlled by proportional pneumatic valves (not shown), which according to the temperature requirement, modulate the thermal fluid flow.

The housing 110 is provided with an insulating cover which prevents heat from escaping into the environment.

The fans (114) are the means used to homogenize the temperature of the oven (11). These 6 designed appliances are arranged in such a way as to ensure a constant oven temperature (11).

The temperature control system is monitored by thermocouples (not shown) arranged at different furnace points (11), and thus monitors the temperature from different points. This information is received by the control system where it is processed. The control mechanism directs the thermal fluid valves to open, close or remain unchanged as required. The control valves are proportional acting, which makes their opening between these points vary from 0% to 100%.

The bars (B) are positioned within the furnace (11) by the arms (121) which carry them through the window (162) of the housing (110) until their positioning in the kiln (112) of the furnace chamber (11). The bars are positioned in recesses (161) of peripheral cylinder crowns (16) (112) and secured by mechanically acting gags (118) in a travel guide which is within the cylinder (112) of the chamber which directs the opening or the closing of the gags (118). Preferably, the displacement of the bar (B) should not exceed 6 centimeters, the tolerance space between the bars (B).

Once the 360 degree rotation of cylinder (112) within the furnace (11) is completed, the bar (B) is cut at each end to a extent specified by a tool (not shown) installed in an attached system which is operated by a sensor when detecting bar (B). This cutting tool is equipped with a high-speed disc, rotates at high speed, and is operated automatically, whose mechanism is pneumatic. When the bar (B) is cut, the debris in the gag is released and eliminated and ready to receive the next bar (B).

The rotor support is composed of an axle concentric that runs through the entire rotor, supported by supports and / or bearings (115), which rest on a structure (116), keeping the moving elements elevated. The furnace heating (11) can be made by any means known to the man of the art, such as steam, oil, electricity or gas.

When heating to electricity, for example, electrical resistors arranged in the air inlets may be installed, heating the furnace (11) to a temperature necessary to post-cure the bar (B).

This temperature is homogenized with temperature controllers and fans. The first hot air stream enters the outlet of the furnace bar (B) (11) of the length of the countercurrent bar length (B), and the second air inlet is in the center of the furnace (11), also counter-current .

The air outlet is almost at the inlet of the bars (B) at the other end of the furnace in a manifold channeling to the chimney (119) (see figure 24) of hot air outlet with the gases that are expelled by curing, these gases are melted on an activated carbon filter, not to throw them into the atmosphere.

When heating with gas, for example, there may be two gas burners (not shown) arranged in the air intakes, which thus heat the direct flame air, with deflectors and flame remains, which causes hot combustion gases. pass through the oven (11) in counter current at the temperature required to cure the bar (B).

The furnace motor and reducer system 11 has a maximum speed resulting from one revolution per hour, which is the duration of the curing process. The reducer-pinion gear, which acts with the spindle gear, discovers the diameter and number of teeth determined in the gear ratio.

At the exit of the furnace (11) the bars (B) are cooled by cold air, so that the bars (B) can be manipulated quickly and proceed to the next step; quality control, by means of electronic elements, and mechanical rays.

Preferably, the present machine comprises a roll holder (13), which as shown in Figures 1 and 2, is a shelf formed from profiles with multiple shelves where several fiber rollers (f) are arranged which are used in the manufacture of the core. from the bar. Said rack is provided with four wheels (131) for easy movement. The number of roll holders used varies according to the need of production, being as many as necessary so as not to lack fiber to feed the machine (1) of raw material.

The wires (f) of a roller rack (13) are joined to those of the next rack (13), while the bars (B) continue to be produced without the need for replacement of raw material.

The lack of raw material causes the machine (1) to stop immediately to avoid production failures by cores (B2) out of specification.

This machine (1) manufactures FRP bars and has pneumatic, hydraulic, mechanical, electronic and electric mechanisms. Its maximum production capacity is 200 bars per hour at a linear speed of 2400 meters per hour with 100% operational efficiency. It operates automatically, with set point temperature, pressure, speed, etc.

The present machine (1) further comprises a support (15) for ready-made bars (B), provided with a plurality of semicircular handles (151) for receiving and accommodating the already cured bars (B) upon leaving the furnace (11). The bars (B) are released from the furnace (11) upon opening of the gags (118), then exit through the window (162) of the carcass (110), and then are deposited nasally (151) until they cool.

The invention further relates to bars (B) obtained in the present machine by the process called incomplete pultrusion and extrusion variant formed from a composite material.

The main features of this bar are: high corrosion resistance whatever the environment, which makes it stainless and durable; They have excellent mechanical strength, withstand breaking loads higher than steel; have a variable modulus of elasticity according to the fibers used; has a higher deformation level than steel; they are of great tenacity and rigidity; they weigh a quarter of what their steel counterpart weighs; have a coefficient of thermal expansion very close to that of steel and concrete; are not conductive to electricity; and do not create magnetic fields because they are not metallic.

Composite material bars (B) are a combination of two or more different materials having a noticeable interphase between them.

These are polymeric materials consisting of a thermostable resin and a fiber reinforcement.

Of the thermoset resins, they are mentioned but not limited to polyester, vinyl ester, epoxy resins, or combinations thereof.

As for reinforcement materials, any material chosen from, but not limited to, fiberglass, carbon, aramid, basalt, their combinations or any other reinforcement fibers may be used.

These FRP (fiber reinforced polymers) bars (B) can be used as reinforcement for concrete.

Being the main characteristics of the bars (B) their high mechanical resistance and their excellent chemical resistance, they can be used to safely, sturdy, durable armarconcreto and very aggressive environments. Traditional steel reinforcements have not been able to solve the corrosion problem, leading to major repair and maintenance costs due to their degradation. Composite materials solve this serious problem, as by not presenting problems in any type of corrosive environment, they considerably increase the life of concrete.

Another feature of these bars is that they are manufactured by a process specifically designed to generate bars of composite material with shoulders.

Resistance tests were performed against steel and composite material manufactured by this process, the results of which are shown in the table below and in Figure 26. As can be seen, the bars of composite material are superior to those of steel.

The mechanical properties of the concrete reinforcing bars are superior to those due to fiber orientation, fiber / resin ratio, bounce (BI) to increase the adhesion as concrete, mechanical and chemical properties of the polymeric binder.

The table below provides a comparison of steel armor, wire rope and composite material cables.

<table> table see original document page 30 </column> </row> <table> <table> table see original document page 31 </column> </row> <table>

Claims (33)

1. MATERIAL BAR MANUFACTURING PROCESS COMPOSITION characterized by the fact that it comprises the following steps: (a) bundling yarns (f) of parallel oriented fibers, (b) applying tension to the bundled yarns (f), (c) yarn bathing (f) ) grouped in thermostable resin, kept in tension, d) Elimination of excess of thermostable resin by compression, and adjustment of resin to fiber ratio e) Formation of core (B2) of bar (B) by means of cold matrix (5) ) (f) Application of a helically resilient resilient fiber cord over the core (B2) with the reinforcement of the shoulders (BI); (g) Initiation of the polymerization process of the thermostable core resin (B2) and the undercuts (BI) , in a linear microwave oven (14); (h) application of a thermostable resin cover at room temperature around the core (B2) and shoulder reinforcements (BI); (i) bar modeling (B); of polime (i) polymerization of the thermostable core resin (B2) with shoulders (BI), still tensioned, at a controlled temperature; (l) post-cure of the bars (b); by heating for about one hour at or above the glass-transfer temperature (tg) of the thermostable bar resin (B). m) Cutting the bars (B) to the desired dimensions; MATERIAL BAR MANUFACTURING PROCEDURE according to claim 1, characterized in that it comprises an initial step of drying the yarn (f) of the fibers prior to the step (b) of their wetting with resin. COMPOSITE MATERIAL BAR MANUFACTURING MACHINE for carrying out the process of any one of claims 1 and 2, characterized in that the following order comprises a first drive system formed by a piston (411) which vertically moves an upper cylinder (312) against a lower cylinder (311), limiting the passage space of the wires (f); a humidifier (3) with wire bath resin (f); resin excess removal presses of the threads (f); a (5) tapered driver or cooler; a spinner (6) of the core (B2) and receiving a strand (c) of fibers positioned around the core (B2) during its advancement in the formation of a shoulder (BI); a first microwave oven (14); a feeder (8) deresin to the core (B2) and cam (BI); a molder (9) from the bar (B); a second microwave oven (14); a second traction system (10) of the bar (B) which are kept tensioned between the first and second traction system (10); and a bar curing oven (11). A MATERIAL BAR MACHINE COMPOSITION according to claim 3, characterized in that it comprises a drying system (2) of the fiber strands (f) prior to the upper cylinder traction system (312) against a lower cylinder (311). which comprises a turbine-type blower (22), a heater (23), a drying chamber (21), and a breather (24). COMPOSITE MATERIAL BAR MANUFACTURING MACHINE according to claim 4, characterized in that the chamber pellet (21) comprises a plurality of yarns (21) for passing the yarns (f). A COMPOSITE MATERIAL BAR MACHINE according to claim 4, characterized in that the chamber (21) comprises a temperature control system. MATERIAL BAR MACHINERY COMPOSITE according to claim 3, characterized in that the humidifier (3) is provided with a pararesin tank (31) with a series of wire-directioning cylinders (311, 312 and 313) for inside and outside the tank (31), where the upper rollers (311 and 312) direct the inlet of the wires (f) to the tank (31); the lower cylinder (311) holds the wires (f) dipped in the resin resin (31), and the rear upper cylinders (313) and (311) direct the wires (f) to the production of the bar (B). A COMPOSITE MATERIAL BAR MACHINE according to claim 7 characterized in that the tank pellet (31) comprises weight-bearing load cells (32). COMPOSITE MATERIAL BAR MACHINE according to claim 7, characterized in that the tank pellet (31) comprises a housing (33) in which two pistons (411 and 412) are fixed through a "U" shaped upper structure (42). which move the upper cylinders (312) and (313) vertically, respectively, to bring them closer or further away from the cylinders (311). MATERIAL BAR MACHINERY COMPOSITE according to Claim 3, characterized in that the extruder pellet is formed by the cylinders (313) and (311) which are approached by the piston (412), limiting the space for passage. impregnated yarn (f). MATERIAL BAR MACHINERY COMPOSITE according to Claim 9, characterized in that the shell (33) comprises an upper part (331) which pivots with respect to the base (332) by means of hinges (330). MATERIAL BAR MANUFACTURING COMPOSITE according to claim 9, characterized in that the shell (33) is anchored to the machine (1) by means of elongated holes. MATERIAL BAR BUILDING MACHINE COMPOSITE according to Claim 3, characterized in that the pivot of the spinner (6) comprises a support shaft (61) of each movable assembly which is drilled by a hole of the same diameter as the largest diameter of the core of the bar. (B) said shaft (61) is mounted on a bearing assembly and these in turn on a bearing carrier (64); a gearmotor (65) generates the movement according to the desired helical pitch (BI); the power output and gearmotor speed (65) is regulated by the pinion (66) which connects the gear (63) to the shaft (61). A COMPOSITE MATERIAL BAR MACHINE according to claim 3, characterized in that it comprises a secondary dampener (7) of the dampening cord (c) prior to its laying around the core (B2) in the spinner (6); the humidifier (7) comprises a resin tank (71), fiber strand (c) steering rollers (72, 73 and 74) within the tank (71), and withdrawal rollers (73) and (74) excess cord resin (c). A MATERIAL BAR MANUFACTURING COMPOSITE according to claim 14, characterized in that it comprises a fiber twist (75) to form a fiber strand (c) before passing through the humidifier (7). The composite material rod machine according to claim 3, characterized in that the feeder rod (8) comprises an axis (81) coupled to an endless screw provided with a core rod through hole (B). The composite material bar machine according to claim 16, characterized in that the feeder (8) further comprises a feeder (85) continuously supplying raw material. COMPOSITE MATERIAL BAR MACHINE according to claim 3, characterized in that the molder (9) comprises molding discs (91) of uniform material distribution and bar formation under compression. COMPOSITE MATERIAL BAR MACHINE according to claim 3, characterized in that the drive system (10) comprises three tractor or drag carriages (101) fixed and pulled by double chains (102), geared to the porcor drive system (103). ; the chains (102) are held taut between two crowns (103) and supported by the frame (105), the drag wagons (101) comprise bar (B) gripping gags (106). A MATERIAL BAR MANUFACTURING COMPOSITION according to claim 19, characterized in that it comprises armrests (12) arranged at the ends of the traction system frame (105) coupled to the drag carriage (101) by means of of a pneumatic piston (122) perpendicular to and moving with the arm carriage (12). The composite material bar machine according to claim 20, characterized in that the mechanical arms (121) comprise four pistons each, one of which is a pistol (123) of a bar grab (127); a piston (125) for raising the arm (121) with the bar (B); the third piston (126) rotating the collet (127) from a vertical position to a horizontal position, and the fourth piston (124) by positioning the bar (B) in the furnace (11). The composite material bar making machine according to claim 21, further comprising a bar-cutting system (129). MATERIAL BAR MANUFACTURING COMPOSITE according to claim 3, characterized in that the furnace pellet (11) has a cylindrical shape and comprises a concentric disc (111) which rotates the cylinder axis (112) of the furnace inner chamber (11). ), which is supported by bars (113); the housing (110) is fixed and supported on the floor, independently of the disk (111), and is provided with fan blowers (114). A MATERIAL BAR MANUFACTURING COMPOSITE according to claim 21, further comprising a roll holder (13) in the form of a four-wheeled rack (131) and a plurality of shelves for positioning the fiber feed wires (f) of bar production (B). MATERIAL BAR MANUFACTURING COMPOSITE according to any one of claims 3 to 24, further comprising two microwave ovens (14), one being positioned after the spinner (6) and the other after the molder (9). 26. Composite material bar characterized in that it is obtainable by the process of any one of claims 1 or 2. 27. COMPOSITE MATERIAL BAR according to claim 26, characterized in that it is made of composite material from a polymeric binder and a fiber reinforcement, with a core (B2) of thermostable resin bonded reinforcing fibers (helically wrapped (B)) by such materials. reinforcement fibers and covered by thermostable thixotropic resin. 28. COMPOSITE MATERIAL BAR according to claim 26, characterized in that the polymeric binder is chosen from thermostable polyester, vinyl ester, epoxide resins or combinations thereof. 29. COMPOSITE MATERIAL BAR according to claim 26 characterized in that reinforcing materials are selected from fiberglass, carbon, aramid, basalt or combinations thereof. 30. Composite material bar according to claim 29, characterized in that the fiber is lightweight and is present in a proportion of 75 to 80% by weight of the total bar. 31. Composite material bar according to claim 29, characterized in that the fiber is decarbon and is present in a proportion of 60 to 70% by weight of the total bar. 32. COMPOSITE MATERIAL BAR according to claim 29, characterized in that the fiber is from amide and is present in a proportion of 60 to 70% in total weight of the bar. 33. COMPOSITE MATERIAL BAR according to claim 29, characterized in that the fiber is debasalt and present in a proportion of 60 to 70% in total weight of the bar.