NL2031905B1

NL2031905B1 - Composite object and reinforced material, and associated methods of manufacturing

Info

Publication number: NL2031905B1
Application number: NL2031905A
Authority: NL
Inventors: Lambertus Van Merksteijn Jacobus
Original assignee: Vm Holding B V
Priority date: 2022-05-18
Filing date: 2022-05-18
Publication date: 2023-11-27

Abstract

The invention relates to a method of manufacturing a composite object. The method comprises providing a ﬁrst member being substantially transparent to radiation of a predeﬁned wavelength and a second member being substantially opaque to radiation of 5 said predeﬁned wavelength, wherein at least one of the at least one ﬁrst member and the second member is fusible. The members are then fused together by bringing the members into contact With each other, and by irradiation the second member through the ﬁrst member. The invention also relates to a composite object obtained using the method, a cured material reinforced with the composite object, and a method of manufacturing the 10 reinforced cured material.

Description

COMPOSITE OBJECT AND REINFORCED MATERIAL, AND ASSOCIATED METHODS OF

MANUFACTURING

The invention relates to a method of manufacturing a composite object. Composite objects are known as such, and can be used for various purposes. An advantage of composite objects is that they may be tailor made to specific purpose by virtue of the composite character. As an example, mechanical properties may be tailored by combining objects into a composite.

Especially when composite objects are to be used for their mechanical properties, it is important the components of the composite object remain integrated with each other, in order to prevent failure of the composite object.

The invention has as its object to provide a method of manufacturing a composite object which results in a reliable integration of the components.

The object is met by a method which comprises performing the following steps in any suitable order and/or concurrently:

A) providing at least one first member being substantially transparent to radiation of a predefined wavelength and a second member being substantially opaque to radiation of said predefined wavelength, wherein at least one of the at least one first member and the second member is fusible;

B) bringing the at least one first and the second member into contact with each other, thereby defining a first contact area of the at least one first member and a second contact area of the second member;

C) irradiating the second contact area of the second member by directing radiation of said predefined wavelength through the at least one first member, thereby heating at least the second member in order to soften or melt at least a part of the at least one first and/or second member at the at least one first or second contact area; and

D) cooling or allowing the at least one first and/or second member to cool, thereby bonding the at least one first and the second member.

The method makes use of the fact that the first and second member have different absorption spectra. By choosing a radiation which is transmitted by one, but not the other member, the method allows fusing one or both of the members by means of radiation passing through said one member. The radiation, and thus the fusing, can accordingly be very local to the contact of the two members. In fact, the radiation may be supplied at the contact area or within the contact area between the members only, so that no material outside the contact area is fused. This may aid in preserving the mechanical or physical properties of the members outside the contact area, or may at the least allow for an efficient use of radiation.

It is noted that the second member is heated by the radiation since it is not transparent to it.

Nevertheless, it is possible the first member softens or melts whilst the second member remains solid, if the melting temperature of the first member is lower than that of the second member. In such a case, heat transmitted from the second member to the first member may cause the first member to soften or melt. It is of course also possible only the second member softens or melts, or that both members soften or melt.

In particular, the radiation used may be light, for instance IR light. In the latter case, the predefined wavelength may correspond, i.e. lie within, the IR spectrum. IR radiation may have a suitable wavelength for softening or melting materials in order to fuse them together as a composite object.

The light may be emitted by a laser. In such a case, the light can be supplied locally thereby increasing efficiency and/or reducing the chance of error outside of the contact area.

The first member may be transparent to radiation of wavelengths other than that of the predefined wavelength, for instance within the IR spectrum. The first member may be transparent for the entire IR spectrum, and possible also or alternatively for the visible light spectrum.

Accordingly, it is possible to inspect the connection between the members via the first member using the naked eye or using IR equipment.

In an embodiment of the method, the method further comprises providing first members on opposing sides of the second member. It is possible to produce composite objects that are relatively strong according to this embodiment.

It is noted that providing the first members on opposing sides is enabled by the method according to the invention, since the it remains possible to heat the contact areas using radiation through the first members, even if they are supplied on both sides of the second member. In particular, this embodiment distinguishes from other production methods in which the second member would be back-heated. Such a method would not allow providing first members on two opposing sides, as one first member would black access to the back of the second member as seen from the opposing first member.

In an embodiment, step C) comprises irradiating along a pattern defined by the at least one first member, preferably only within said pattern.

The pattern may ensure that radiation is focused on the contact surface.

In another embodiment, step C) comprises irradiating along an axis normal to the first and second contact area. Accordingly, the irradiation is limited to the contact area of the first and second member.

The second member may be a sheet. The sheet may serve to provide a relatively large area over which the composite object may span.

The first member may be a strip. Using a strip, mechanical properties in a single direction may be tuned.

The second member may be provided with a ribbed pattern or a rough pattern.

Such a surface finish may enhance interaction with other objects, such as the first member.

For that reason, the rubbed or rough surface of the second member may comprise the second contact area. In that case, contact between the first and second member may be enhanced.

The ribbed or rough area may additionally or alternatively comprise a part outside of the contact area, so as to allow enhancing contact with material other than the first member(s).

The the at least one first member and/or the second member may comprise PE or similar material. PE is suitable as material for many purposes. More importantly, it may have the correct transmitting properties to connect the components by radiation.

If first and second member are both of PE, an easily recyclable composite object is obtained.

The at least one first member may comprise UHMWPE (e.g. Dyneema). UHMWPE may be transparent to suitable radiation and allow connecting via the claimed method. Moreover,

UHMWPE may not be negatively affected (to a large extent) by the method described herein.

The invention also relates to a composite object obtained by the method. As such, the composite object described herein may have all features, in any suitable combination or alone, corresponding to the method as described above.

The composite object comprises a first and a second member, the first member being substantially transparent to light of a predefined wavelength the second member being opaque to light of the predefined wavelength, wherein the first and the second member are bonded together within a first contact arca of the at least one first member and a second contact area of the second member respectively, by softening or melting of at least a portion of the first and/or second contact area.

In particular: - The light of the predefined wavelength may be IR light; and/or - Multiple first members may be arranged on opposing sides of the second member; and/or - The second member may be a sheet and/or wherein the first member is a strip; and/or - At least one main surface of the second member may be provided with a ribbed pattern or a rough pattern; and/or - the ribbed main surface of the second member may comprise the second contact area; and/or - the at least one first member and/or the second member may comprise PE or similar maternal; and/or - the at least one first member may comprise UHMWPE, such as Dyneema.

The invention also relates to a reinforced material, comprising a cured material reinforced with a composite object as described herein, alternatively or preferably obtained using the method as described herein.

The reinforced material may benefit from the properties of the cured material, having been enhanced by the advantageous properties of the composite object as described herein.

To enhance the cooperation of the cured material and the composite object, the composite object may be pretensioned in the cured material.

The cured material may be concrete. Accordingly, a building material is obtained that is able to replace steel-reinforced concrete. The reinforced material described herein may be more environmentally friendly than steel-reinforced concrete, as steel has a high impact on the environment. It is noted that even if the material of the composite object is obtained from fossil resources, the carbon present therein remains within the concrete and does therefore not make its way to the atmosphere and thus does not contribute to greenhouse emissions.

Finally, the invention relates to a method of manufacturing a reinforced cured material, comprising the steps of: a. providing a composite object as described herein; b. casting a curable material around the composite object; and c. curing the curable material to form the reinforced cured material.

The method may be performed with a composite object having any one or more of the above-described features, in any suitable combination or alone. For instance, the composite object is pretensioned.

The invention will be further described with reference to the drawings, in which:

Figures 1A and 1B schematically show a cross section of a part of a composite object being irradiated;

Figure 2 schematically shows a top view of a composite object;

Figure 3 schematically shows a cross section of a reinforced material;

Figure 4 schematically shows absorption spectra of first and second members of a composite object;

Figure 5 schematically shows a flow chart for performing a method of manufacturing a composite object; and

Figure 6 schematically shows a method of manufacturing a reinforced material.

Throughout the figures, like elements are referred to using like reference numerals.

Figures 1A and 1B show a composite object 1 with a first member 2 and a second member 3. In this case, the first member 2 is a strip and the second member 3 is a sheet. Radiation 4 is supplied from directly above the first member 2 at a right angle with respect to the surface of the first member 2 and the second member 3. The radiation 4 has a predefined wavelength 21. As can 5 be seen from dashed lines 9 in figure 1B, the first member 2 is transparent for the radiation 4. Thus, the radiation 4 passes through the first member 2 and reaches the second member 3. The second member 3 is opaque to the radiation 4 of the predefined wavelength 2. As such, the radiation 4 is at least partially absorbed, causing a local heating of the second member 3. As a result, the second member 3 locally melts, as is shown by melting area 6. The melting of the second member 3 causes the material of the second member 6 to fuse to the first member 2, thereby creating a reliable connection between the first member 2 and the second member 3 once the materials have cooled.

By focusing the radiation at the location of the first member 2, the melting area 6 is limited to the contact area’s of the first and second members 2, 3. As such, the melting area is within the contact area 7 of the first member 2, which is defined as the surface of the first member 2 in contact with the second member, and the to the contact area 8 of the second member 3, which is defined as the surface of the second member 3 in contact with the first member 2.

In the example of figures 1A and 1B, the radiation is IR light produced by a laser 5. The first member 2 is furthermore transparent to the visible spectrum of light as well. It is noted that additional first members 2 can be arranged on the second member, for instance on the same and opposing sides thereof. The first member 2 and the second member 3 are both made from PE. In this example, the first member 2 is made from UHMWPE, e.g. Dyneema. The second member 3 is made form a different PE, for instance a less high-performance PE compared to the first member 2.

Figure 2 shows a top view of a composite object 1, which shows a sheet as second member 3 and a several strips as first members 2. The top surface of the second member 3 is provided with aribbed pattern inside and outside of its contact area with the first members 2.

Figure 3 shows a reinforced material 10, which comprises a cured material 11, in this case concrete, reinforced with a composite object 1, for instance that described herein. The composite object 1 is pretensioned.

Figure 4 shows exemplary absorption spectra u for the first member u: and for the second member u». The x-axis represents the wavelength 2 of radiation, whereas the y-axis represents the amount of absorption u at that wavelength 2. As shown, the absorption for the first member ui is relatively low at a predetermined wavelength 1. Radiation of this wavelength %; is transmitted by the first member, which is therefore substantially transparent for the predefined wavelength 2}; (the first member is not or substantially not reflective). The absorption for the second member u: is relatively high at the predefined wavelength %;. Accordingly, the second member is substantially opaque for radiation of this wavelength %;. As such. energy from inbound radiation is absorbed,

and converted to heat which melts the material. The second member is also not (substantially) reflective. It is noted that the absorption outside of the predefined wavelength i; is of less relevance. As long as the first member is sufficiently transparent, and the second member is sufficiently opaque at the predetermined wavelength 2. the invention is applicable. It is for instance possible to first member is transparent over the entire IR spectrum, or the visible and IR spectrum.

Figure 5 shows a flowchart 100 for a method of manufacturing a composite object. The method comprises a first step 101, a second step 102, a third step 103 and a fourth step 104. The steps 101, 102, 103, 104 can be performed in any suitable order or at least partly concurrently. The first step 101 comprises providing at least one first member being substantially transparent to radiation of a predefined wavelength and a second member being substantially opaque to radiation of said predefined wavelength, wherein at least one of the at least one first member and the second member is fusible. The second step 102 comprises bringing the at least one first and the second member into contact with each other, thereby defining a first contact area of the at least one first member and a second contact area of the second member. The third step 103 comprises irradiating the second contact area of the second member by directing radiation of said predefined wavelength through the at least one first member, thereby heating at least the second member in order to soften or melt at least a part of the at least one first and/or second member at the at least one first or second contact area. The fourth step 104 comprises cooling or allowing the at least one first and/or second member to cool, thereby bonding the at least one first and the second member.

Figure 6 shows a flowchart 200 for a method of manufacturing a reinforced cured material.

The method comprises a first step 201, a second step 202, and a third step 203. The steps 201, 202, 203 may can be performed one after the other in any suitable order, or at least partly concurrently.

The first step 201 comprises providing a composite object as described herein. The second step 202 comprises casting a curable material around the composite object. The third step 203 comprises curing the curable material to form the reinforced cured material.

Although the invention has been described above with reference to specific examples and embodiments, the invention is not limited thereto. Instead, the invention is also described by the claims.

Claims

Conclusions

1. Method for manufacturing a composite object, the method comprising performing the following steps in any suitable order and/or simultaneously: A) providing at least one first member that is substantially transparent to radiation from a predetermined wavelength and a second member that is substantially opaque 1s to radiation of the predetermined wavelength, wherein at least one of the at least one member and the second member is fusible; B) bringing the at least one first member and the second member into contact with each other, and thereby defining a first contact surface of the at least one first member and a second contact surface of the second member: C) irradiating the second contact surface of the second member by sending radiation with the predetermined wavelength through the at least one first member, and thereby heating at least the second member to at least part of the at least one first member and/or the second to melt or soften a member at the location of the at least one first contact surface or the second contact surface; and D) cooling or allowing the at least one first and/or second member to be cooled. and thereby binding the at least one first paragraph and the second paragraph.

2. Method for manufacturing a composite object according to claim 1, wherein the radiation is light, preferably IR light.

3. Method for manufacturing a composite object according to any one of the preceding claims, wherein the radiation is emitted by a laser.

4. Method for manufacturing a composite object according to any one of the preceding claims, wherein the predetermined wavelength corresponds to the IR spectrum.

5. Method for manufacturing a composite object according to any one of the preceding claims, wherein the at least one first member is substantially transparent to radiation with wavelengths other than the predetermined wavelength, for example within the IR spectrum.

6. Method for manufacturing a composite object according to any one of the preceding claims, further comprising providing first members on opposite sides of the second member.

7. Method for manufacturing a composite object according to any one of the preceding claims, wherein step C) comprises irradiating along a path determined by the first member, preferably exclusively in that path.

8. Method for manufacturing a composite object according to any one of the preceding claims, wherein step C) comprises irradiating along an axis perpendicular to the first and second contact surfaces.

9. Method for manufacturing a composite object according to any one of the preceding claims, wherein the second member is a sheet.

10. Method for manufacturing a composite object according to any one of the preceding claims, wherein the at least one first member is a strip.

11. Method for manufacturing a composite object according to any one of the preceding claims, wherein at least one main surface of the second member is provided with a ribbed pattern or a rough pattern.

12. Method for manufacturing a composite object according to the previous claim, wherein the ribbed main surface of the second member comprises the second contact surface.

13. Method for manufacturing a composite object according to any one of the preceding claims, wherein the at least one first member and/or the second member comprises PE or a comparable material.

14. Method for manufacturing a composite object according to the previous claim, wherein the at least one first member is UHMWPE, such as Dyneema. includes.

15. Composite object comprising a first and a second member, wherein the first member is substantially transparent to light of a predetermined wavelength, wherein the second member is opaque to light of the predetermined wavelength, wherein the first and second members are bonded together are bonded within a first contact surface of the at least one first member and a second contact surface of the second member, respectively, by softening or melting at least a part of the first and/or second contact surface.

The composite object of claim 15, wherein the predetermined wavelength is IR light.

17. Composite object according to claim 15 or 16, wherein several first members are arranged on opposite sides of the second member.

18. Composite object according to any one of claims 15 - 17, wherein the second member is a sheet and/or wherein the first member is a strip.

19. Composite object according to any one of claims 15 - 18, wherein at least one main surface of the second member is provided with a ribbed pattern or a rough pattern.

20. Composite object according to the previous claim, wherein the ribbed main surface of the second member comprises the second contact surface.

21. Composite object according to any one of claims 15 - 20, wherein the at least one first member and/or the second member comprises PE or a comparable material.

22. Composite object according to any one of claims 15 - 21, wherein the at least one first member comprises UHMWPE, such as Dyneema.

23. Reinforced material, comprising a hardened material that has been reinforced with a composite object according to any one of claims 15 - 22.

24. Reinforced material according to the previous claim, wherein the composite object is prestressed in the hardened material.

25. Reinforced material according to claim 23 or 24, wherein the hardened material is concrete.

26. Method for manufacturing a reinforced hardened material. including the steps of:

a. providing a composite object according to any one of claims 15 - 22;

b. casting a curable material around the composite object: and

¢. curing the curable material to form the reinforced cured material.

27. Method according to the previous claim. whereby the composite object is prestressed.