EP1789641A2 - Structures fibreuses unitaires avec elements de retenue circonferentiels fonctionnels - Google Patents

Structures fibreuses unitaires avec elements de retenue circonferentiels fonctionnels

Info

Publication number
EP1789641A2
EP1789641A2 EP05791516A EP05791516A EP1789641A2 EP 1789641 A2 EP1789641 A2 EP 1789641A2 EP 05791516 A EP05791516 A EP 05791516A EP 05791516 A EP05791516 A EP 05791516A EP 1789641 A2 EP1789641 A2 EP 1789641A2
Authority
EP
European Patent Office
Prior art keywords
construct
fibers
reinforcing
filaments
reinforcing filaments
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP05791516A
Other languages
German (de)
English (en)
Inventor
Paul Schmidt
Gene Lamb
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Avintiv Specialty Materials Inc
Original Assignee
Polymer Group Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Polymer Group Inc filed Critical Polymer Group Inc
Publication of EP1789641A2 publication Critical patent/EP1789641A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
    • E04C5/073—Discrete reinforcing elements, e.g. fibres
    • E04C5/076—Specially adapted packagings therefor, e.g. for dosing
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • C04B40/0039—Premixtures of ingredients
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0068—Ingredients with a function or property not provided for elsewhere in C04B2103/00
    • C04B2103/0077—Packaging material remaining in the mixture after the mixing step, e.g. soluble bags containing active ingredients

Definitions

  • the present invention is directed to unitized fibrous constructs for reinforcing castable mixtures, such as cementitious matrices or mixtures and, more particularly a unitized fibrous construct in which the circumferential retaining element that retains a bundle of reinforcing fibers or filaments also serves as a reinforcing element upon mixture into the castable mixture.
  • Relatively large diameter fibers for example, in excess of 40 to 60 microns in diameter, can be added to a cementitious mixture such as a wet concrete blend, dispersed in the blend by mechanical agitation, followed by pouring and curing of the concrete.
  • Large diameter fibers serve to reinforce the concrete after it has been cured, by providing additional tensile strength and minimizing impact damage and crack propagation.
  • Small diameter fibers typically less than 30 to 40 microns in diameter, and having a relatively high surface area, are commonly added to concrete mixes in order to reduce the development of small elastic shrinkage cracks in the concrete during the curing period. The problem of crack development is known to occur as a result of uneven curing of the concrete.
  • the fibrous components used typically in the practice of reinforcing cementitious mixtures include specifically thermoplastic synthetic fibers of finite staple length, such as polypropylene staple fibers.
  • the corresponding performance of the binding agent is based upon application of the binding agent to the reinforcement fibrous components such that the binding agent is both uniformly applied to the majority of the fibers so as to obtain equivalency within the batch, and that no excess binding agent is introduced as such will adversely effect the ability of the reinforcement fibrous components to disengage and distribute homogeneously.
  • binding agents One other determent encountered in the use of binding agents is that air is often entrained within the micro-bundles upon application and agglomeration of the staple fibers. When such micro-bundles are subjected to mechanical mixing, the entrained air is released as a foam, which reasonably compromises the ability of the cementitious mixture to cure uniformly.
  • Cellulosic tapes have also been utilized to retain reinforcement fibers; however, such tapes can become problematic for a cementitious matrix or mixture as well. See for example United States Patent No. 5,807,458, entitled, "Reinforcing Elements for Castable Compositions", issued September 15, 1998, in the name of inventors Sanders et al.
  • the cellulose tape is prone to degradation in the alkaline environment of the mixture. Degradation of the tapes may introduce void spaces within the mixture which can negatively impact uniform curing of the cement. Further, the wet cellulose tapes can promote mold growth within the mixture that can lead to cracks in the setting mix.
  • circumferential binding elements have been utilized to provide temporary retention of fibrous constructs, as disclosed in commonly assigned U.S. Patent Publication 2004/0244653, entitled “Unitized Fibrous Concrete Reinforcement”, filed on December 9, 2004, in the name of inventors Schmidt et al, which is herein incorporated by reference as if set forth fully herein.
  • the circumferential binding element was purposeful as a retaining element, but did not contribute incremental functionality within the cementitious matrix.
  • the present invention is directed to unitized fibrous constructs for reinforcement in a castable compound, such as a cementitious matrices or mixtures.
  • the invention provides for a construct that includes a bundle of reinforcing fibers or filaments surround, at least partially, by a retaining element, which also serves the dual purpose, upon addition to the cementitious mixture, of acting as a reinforcing element.
  • the retaining element does not need to dissolve or otherwise be dispersible upon addition to the cementitious mixture. As such, degradation issues with dispersible materials are eliminated, such as issues related to void spaces in the mixture and possible mold issues leading to crack propagation.
  • a unitized fibrous construct for reinforcing a cementitious mixture includes a plurality of reinforcing filaments or fibers oriented in a generally parallel relationship such that the plurality of reinforcing filaments or fibers form a unit having a circumferential exterior surface.
  • the unit will those typically form the geometry of a cylindrical bundle of filaments or fibers, although other geometries of the unit are herein contemplated and within the bounds of the present invention.
  • the construct also includes a retaining element that serves as a reinforcing element in the cementitious mixture.
  • the retaining element surrounds at least a portion of the circumferential exterior surface and retains the plurality of reinforcing filaments or fibers prior to adding the construct to the cementitious mixture.
  • the circumferential retaining element aids in maintaining the integrity of the unitized fibrous construct, and the fibrous component therein, for purposes of shipment, measurement, and dosing into a cementitious mixture.
  • the retaining element will be spirally wound around the plurality of fibers or filaments, such that the retaining element provides temporal retention of the bundle of fibers or filaments prior to immersion in the cementitious mixture.
  • the retaining element will be formed of a similar material, and in some embodiments the identical material, as is used to form the reinforcing fibers or filaments.
  • the circumferential retaining element may be selected from suitable materials that are considered structurally beneficial to a cementitious matrix by providing additional reinforcement, minimize impact damage, and crack propagation.
  • suitable materials that are considered structurally beneficial to a cementitious matrix by providing additional reinforcement, minimize impact damage, and crack propagation.
  • Such fibrous or filamentary material at least partially or may entirely include super absorbent polymers, splittable fiber or filaments, and fiber or filaments with three- dimensionality, such as coiled or crimped.
  • such materials may consist of thermoplastic, thermoset and partially soluble resins, which are subject to mechanical failure when a corresponding stress and/or solvency threshold is exceeded.
  • the material selected may also be mechanically modified, as exemplified by fibrillation, drawing, perforation, crimping, embossing or molding, so as to exhibit performance attributes in the cementitious matrix such as a reinforcement or elastic shrinkage crack reduction.
  • Various geometries may be employed in the application of the circumferential retaining element, including without limitation, continuous or discontinuous filaments, ribbons, or sheets, which circumscribe the combined, essentially parallel reinforcing fibrous components. It is within the purview of the present invention that the composition of the circumferential retaining elements and of one or more of the reinforcing fibrous components need not necessarily be the same.
  • the retaining element may be placed under additional tension by means of twisting the retaining element. Placing additional tension on the retaining element facilitates the mechanical removal of the retaining element upon mechanical agitation, which then enhances the fiber distribution within a cementitious mixture.
  • the present embodiment includes a single retaining element it is possible, and within the inventive concepts herein disclosed, for more than one retaining element to be used in connection with a single unitized reinforcing construct. For example, two reinforcing elements may be spirally wound around the unit of fibers or filaments in a double-helix type arrangement.
  • the reinforcing filaments are continuous filaments and in fiber embodiments the fibers are finite staple-length fibers. Additionally, the reinforcing filaments may be characterized as fibrillated reinforcing filaments. The reinforcing filaments or fibers may be imparted with tension during processing to insure that the degree of dispersion necessary occurs once the bundle of filaments or fibers are free from retention within the cementitious mixture. In alternate embodiments the reinforcing filaments or fibers may be splittable filaments or fibers or may be formed from a super absorbent polymer composition.
  • the unitized fibrous construct for reinforcing a cementitious mixture includes a plurality of reinforcing filaments or fibers oriented in a generally parallel relationship such that the plurality of reinforcing filaments or fibers form a unit having a circumferential exterior surface.
  • the construct also includes a retaining element formed of one or more splittable filaments that surround at least a portion of the circumferential exterior surface and retains the plurality of reinforcing filaments or fibers prior to adding the construct to the cementitious mixture.
  • the splittable filaments will provide reinforcing capabilities once they have been added to the cementitious mixture
  • the reinforcing filaments or fibers may have a composition similar to or identical to the composition of the splittable filament retaining element. Additionally, the plurality of reinforcing filaments or fibers may be defined as fibrillated reinforcing filaments, which may be imparted with tension to further encourage dispersion upon release from the retaining element. The reinforcing filaments or fibers may further be defined as being formed from a super absorbent polymer composition. [0019] In yet another embodiment the unitized fibrous construct for reinforcing a cementitious mixture includes a plurality of reinforcing filaments or fibers oriented in a generally parallel relationship such that the plurality of reinforcing filaments or fibers form a unit having a circumferential exterior surface.
  • the construct also includes a retaining element formed of a super absorbent polymer composition that surrounds at least a portion of the circumferential exterior surface and retains the plurality of reinforcing filaments or fibers prior to adding the construct to the cementitious mixture.
  • a retaining element formed of a super absorbent polymer composition that surrounds at least a portion of the circumferential exterior surface and retains the plurality of reinforcing filaments or fibers prior to adding the construct to the cementitious mixture.
  • the super absorbent polymer composition retaining elements will provide reinforcing capabilities once they have been added to the cementitious mixture.
  • the reinforcing filaments or fibers may have a composition similar to or identical to the composition of the super absorbent polymer composition retaining element. Additionally, the plurality of reinforcing filaments or fibers may be defined as fibrillated reinforcing filaments, which may be imparted with tension to further encourage dispersion upon release from the retaining element. The reinforcing filaments or fibers may further be defined as being formed from a super absorbent polymer composition.
  • the present invention is able to provide for a cementitious reinforcing construct that includes a retaining element that imparts reinforcing structure into the cementitious mixture.
  • a construct benefits from not having a retaining structure that disperses or otherwise dissolves in the aqueous cementitious mixture and imparts possible negative side-effects to the cementitious mixture, such as voids, strength reducing mold and the like.
  • the reinforcing aspect of the retaining element provides for a construct that is able to provide additional per unit reinforcement of the cement mixture.
  • Figure 1 is an illustrative embodiment of the unitized fibrous construct of the present invention.
  • the unitized fibrous construct 10 is defined herein as a construct including a plurality of oriented reinforcing continuous filaments or finite staple length fibers 12.
  • the filaments or fibers 12 are arranged in a general parallel relationship such that the filaments or fibers form a bundle. While the bundle will typically have a general cylindrical shape, the bundle may also have any other shape, for example oval, square, triangular, etc.
  • the plurality of filaments or fibers 12 will be bundled such that they form a circumferential exterior surface 14.
  • the construct further includes one or more retaining elements 16 that surround at least a portion of the circumferential exterior surface 14 and serve to retain the reinforcing filaments or fibers 12 prior to adding the construct 10 to a castable mixture, such as a cementitious mixture.
  • the retaining element will serve as a reinforcing element upon once added to the castable mixture, such as a cementitious mixture.
  • the retaining element 16 In order for the retaining element 16 to serve as a reinforcing element upon addition to the castable mixture the retaining element will typically be formed of a similar, and in some embodiments identical, fibrous or filamentary material, denier, and length as the reinforcing fibers or filaments 12. Further still, in alternate embodiment the retaining element 16 may be of a dissimilar fibrous or filamentary material, denier, and length as the reinforcing fibers or filaments 12. In those embodiments in which the retaining element is a dissimilar fibrous or filamentary material compared to the reinforcing fibers or filaments, the retaining element will be formed of a material that allows for the retaining element to provide reinforcing characteristics upon addition to the castable mixture.
  • the unitized fibrous construct of the present invention is formed from a plurality of reinforcing fibrous or filamentary components and one or more circumferential retaining elements.
  • the composition of such reinforcing fibers and circumferential retaining element may be formed from any suitable synthetic polymers, including, but not limited to, thermoplastic and thermoset polymers, including polyesters, polyolefins, such as polypropylene and polypropylene copolymers, polyethylene and polyethylene copolymers, polyamides, polyimides, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol, ethylene vinyl alcohol, polyacrylates, copolymers thereof, and the combinations thereof.
  • reinforcing fibers or filaments and the circumferential retaining element may be formed from any suitable natural fibers, including, but not limited to rayon, cotton, pulp, flax, and hemp and the combinations thereof.
  • a particularly preferred embodiment of the present invention is directed to reinforcing fibers or filaments including polyolefin thermoplastic resins.
  • the retaining element that surrounds a portion of the exterior surface includes splittable filaments, which may be of similar or dissimilar polymeric composition in relation to the reinforcing fibers or filaments.
  • splittable fibers are taught in United States Patent No. 6,838,402, issued on January 4, 2005, in the name of inventors Harris, et al.; United States Patent No. 6,746,766, issued on June 18, 2004, in the name of inventors Bond, et al.; United States Patent No. 6,743,506, issued on June 1 , 2004, in the name of inventors Bond et al.; and United States Patent No. 6,444,312, issued on September 9, 2002, in the name of inventor Dugan, all of which are herein incorporated by reference as if set forth fully herein.
  • the plurality of reinforcing filaments may be fibrillated, wherein the filaments may be fibrillated by any conventional fibrillation technique, such as by mechanical fibrillation described in United States Patent No. 3,302,501 , issued on February 7, 1967, in the name of inventor Greene; United States Patent No. 3,496,260, issued February 17, 1970, in the name of inventors Guenther et al.; United States Patent No. 3,550,826, issued December 29, 1970; in the name of inventor Salmela; and United States Patent No. 3,756,484, issued September 4, 1973, in the name of inventor Guenther, or by fluid and sonic fibrillation as disclosed in United States Patent No.
  • reinforcing filaments may be imparted with tension by way of twisting the filaments as well. Tension imparted in the reinforcing filaments will cause greater dispersion of the filaments once the retaining element has been removed from the construct/bundle of filaments.
  • the plurality of reinforcing fibers or filaments may be formed from a super absorbent polymer composition.
  • Exemplary super absorbent polymers are disclosed in United States Patent No. 5,145,609, issued September 8, 1992, in the name of inventor Chambers; United States Patent No. 4,820,773; issued April 11 , 1989, in the name to inventors Alexander et al.; and United States Patent No. 4,645,039, issued March 31 , 1997; in the name of inventor Brandt et al., all of which are herein incorporated by reference as if set forth fully herein.
  • the retaining element that surrounds a portion of the exterior surface may include a super absorbent polymer composition.
  • exemplary super absorbent polymers are disclosed in the previously referenced and incorporated patents.
  • the reinforcing fibers may include splittable fibers. Suitable splittable fibers are taught in the previously referenced and incorporated patents.
  • the retaining element surrounds at least a portion of the circumferential exterior surface of the construct. Once formed, the retaining element aids in maintaining the integrity of the unitized fibrous construct, and the reinforcing fibrous component therein, for the purposes of shipment, measurement, and dosing into a cementitious mixture. Upon mechanical agitation, and optionally exposure to appropriate solvents, the unitized fibrous construct in a cementitious mixture, the retaining element are disrupted, allowing for the homogenous release, distribution, and disbursement of the reinforcing fibrous component into the overall cementitious mixture.
  • the unitized fibrous construct of the present invention is believe to reduce plastic shrinkage cracking by at least 10% per ASTM 1399, Obtaining Average Residual Strength of Fiber Reinforced Concrete.
  • a preferred, though non-limiting, method is taught in part by United States Patent No. 4,228,641 , issued on October 1 , 1980, in the name of inventors O'Neil, this patent is herein incorporated by reference as if set forth fully herein.
  • the '641 O'Neil patent teaches a twine including a core bundle of synthetic monofilaments circumscribed by a synthetic material in a thin band form spirally wound about the monofilaments.
  • the dimensions of the retaining element is defined in terms of the overall circumference of the exterior surface formed by the reinforcing fibers or filaments, as based on the quantity and relative denier of the individual reinforcing fibrous components, and of length, as based on the greatest finite staple length of the cumulative combination of reinforcing fibrous components.
  • Suitable overall circumferences and lengths of the circumferential retaining elements formed in accordance with the present invention may reasonably range from 3 mm to 150 mm and from 8 mm to 100 mm, respectively.
  • circumferential retaining elements exhibit an overall diameter of between 3mm and 30mm and lengths of between 12 mm and 50 mm may be utilized.
  • the circumferential retaining elements may exhibit a width preferably about 1%-50% of the total diameter of the unitized fibrous construct, more preferably about 3%-40% of the total diameter of the unitized fibrous construct, and most preferably about 5%-30% of the total diameter of the unitized fibrous construct.
  • the circumferential retaining element is preferably about 2%-50% by weight of the unitized construct including parallelized reinforcement fibers, more preferably of about 6%-40% by weight of the unitized construct, and most preferably of about 8%-30% weight of the unitized construct.
  • the circumferential retaining element may include one or more continuous or discontinuous filaments, ribbons, or sheets of varying thicknesses that retain the reinforcing fibrous components by a plurality of wrapping techniques so as to expose more or less fiber to the external environment.
  • two thin circumferential retaining elements may be used in a double helix wrapping technique, whereby two circumferential retaining elements criss-cross back and forth about the circumference of the fibrous components.
  • the present invention is able to provide for a cementitious reinforcing construct that includes a retaining element that imparts reinforcing structure into the cementitious mixture.
  • a construct benefits from not having a retaining structure that disperses or otherwise dissolves in the aqueous cementitious mixture and imparts possible negative side-effects to the cementitious mixture, such as voids, strength reducing mold and the like.
  • the reinforcing aspect of the retaining element provides for a construct that is able to provide additional per unit reinforcement of the cement mixture.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

Cette invention concerne une structure fibreuse unitaire pour le renforcement de constructions moulables, telles que des constructions en ciment. Cette structure comprend un faisceau de fibre ou de filament de renforcement qui sont maintenus en place avant l'adjonction du mélange de ciment par un élément de retenue. L'élément de retenue est constitué d'une composition telle que, lors de l'adjonction du mélange de ciment, il confère des propriétés de renforcement à la construction en ciment. Ainsi, cette structure offre des propriétés de renforcement supplémentaire et réduit le risque d'effets secondaires nuisibles attribués à des éléments de retenue qui, dans d'autres circonstances, se dissolvent ou se dispersent dans le mélange de ciment.
EP05791516A 2004-08-20 2005-08-19 Structures fibreuses unitaires avec elements de retenue circonferentiels fonctionnels Withdrawn EP1789641A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US60309104P 2004-08-20 2004-08-20
PCT/US2005/029496 WO2006023698A2 (fr) 2004-08-20 2005-08-19 Structures fibreuses unitaires avec elements de retenue circonferentiels fonctionnels

Publications (1)

Publication Number Publication Date
EP1789641A2 true EP1789641A2 (fr) 2007-05-30

Family

ID=35968191

Family Applications (1)

Application Number Title Priority Date Filing Date
EP05791516A Withdrawn EP1789641A2 (fr) 2004-08-20 2005-08-19 Structures fibreuses unitaires avec elements de retenue circonferentiels fonctionnels

Country Status (3)

Country Link
US (1) US20060070341A1 (fr)
EP (1) EP1789641A2 (fr)
WO (1) WO2006023698A2 (fr)

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Also Published As

Publication number Publication date
WO2006023698A3 (fr) 2007-06-14
WO2006023698A2 (fr) 2006-03-02
US20060070341A1 (en) 2006-04-06

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