US20070256382A1

US20070256382A1 - Armature for composite and polymeric materials domain of the invention

Info

Publication number: US20070256382A1
Application number: US11/387,123
Authority: US
Inventors: Luc Drolet
Original assignee: ECOPLAST Inc
Current assignee: ECOPLAST Inc
Priority date: 2005-03-17
Filing date: 2006-03-23
Publication date: 2007-11-08
Also published as: CA2499847A1

Abstract

The present invention consists of an assembly of materials, particularly wood-plastic composite or polymer for construction or building purposes, consisting in a matrix of these materials wherein a rod is inserted, a cable or a chord of reinforcement in a place of the tension loads, to increase the total capacity of mechanical resistance of the assembly and more particularly flexural properties. The invention thus consists of a solidified matrix using one or several rods inserted in the matrix so that the rod takes the tension stresses to increasing resistance to bending. A hardening resin may be injected in the place of a rod, or combined with it. The rods are inserted in the area undergoing the maximum of tension or at any other place in order to offer durability and an increased resistance. Various configurations of assemblies can be used, such as for example, a T, an I, a M, a H or any other form of section.

Description

DOMAIN OF THE INVENTION

This invention belongs to the fields of building materials, industrial materials and the reinforcements of beams in order to avoid the bending of these materials often confronted with a tension under a neutral axis, which can cause ruptures. It can be used as well by contractors than by occasional carpenters. The reinforcement of structure is useful in many fields of which that of the building of decking, patios and terraces.

PRIOR ART

A search of prior art revealed the following patents:
CA 1,234,703; Studinka, 1988, presents a mixture of fibres of reinforcement for building materials which harden with water.
CA 2,147,038; Fantino, 1999, presents a process and a machine for the realization of a reinforcement in the shape of block and including a weaving of wire of reinforcement, for a composite part.
CA 1,149,240; Kober, 1983, presents a method of manufacture of vegetal fibre and reinforcement for building materials of mineral origin, using lime and silicates.
CA 2,142,155; Baravian, 1995, presents a manufacturing process of a textile double-layer reinforcement intended for bituminous covers.
CA 2,089,208; Cahuzac, 2002, presents a process for the realization of a fibre mattress for composite matter parts.

OBJECTIVES AND ADVANTAGES

This invention is a building material designed to avoid excessive bending of structures often confronted with tension stresses under neutral axis that can cause ruptures. The invention consists of a solidified form using a rod inserted through a composite materials or a polymer in order to take the tension stresses to increase flexural resistance or tensile strength. The rods are inserted in the part undergoing the maximum of tension stresses or at any other place in order to offer an increased resistance.

ADVANTAGES

A wide range of applications particularly outside in places exposed to rain and bad weather. Wood plastic composites or polymers are usually resistant to water absorption, to mildew or other deteriorations and can be even covered by a coextruded protective coating. Decking and patios using this invention can be built with longer spans thanks to the insertion of the rods. It is recommended to calculate the efforts for each application to increase the mechanical resistance of the product, particularly flexural applications. The rods bring a security aspect in case of rupture of the matrix, by retaining a broken assembly.

IDENTIFICATION OF THE DRAWINGS

Relative to drawings which illustrate embodiments of the invention
FIG. 1 is a perspective of a structural block, with partial cut.
FIG. 2 is an end view, section area cut of the structure of FIG. 1
FIG. 3 is a perspective of a T beam, with partial cut
FIG. 4 is an end cut view, section area of the T beam of FIG. 3
FIG. 5 is a cut view of a reversed U shape beam.
FIG. 6 is a cut view of an M shape beam
FIGS. 7A, 7B, 7C are end views with partial cuts of alternatives
FIGS. 8A, 8B are end views and FIG. 8C a perspective of a spread beam
FIGS. 9A, 9B are cut views of alternatives, FIG. 9B being of a siding.

DETAILED DESCRIPTION OF THE DRAWINGS

In the following description and in the related drawings, similar numbers refer to identical parts in the different figures.
FIG. 1 shows a structural assembly 20 having a hollow block shape 24, with a flat part disposed horizontally. One sees a section area 42 and a longitudinal spread 44. Voids 45 make the block hollow. One sees a structural matrix 40 below which there is a lower part 46. In the lower part there are two reinforcing rods 48. In a part cut for better visualizing, one sees a rod surface 50 which acts as a rod adhesive 52 when it is joined to the lower part 46.
FIG. 2 shows in section area 42 of the block shape 24 several voids 45 and walls 47. One sees on the sides a pair of mortises 38 and in the lower part two reinforcing rods 48.
FIG. 3 shows with an arrow a T shape 27 which has two rods located in chosen areas, of which a reinforcing rod 48 in the lower part and a central rod 49 towards the centre of the section. Either rod is preferably inserted at the moment of the extrusion of a beam in an profiled matrix. One remarks around the reinforcing rod 48 a contact surface 53 coinciding with the material of the T shape 27. The lower end of the T shape 27 shows a palm foot 54. The central rod 49 is located practically in the centre of the section. One sees within a cut area close to the centre a screw shape rod 57 and an abrasive rod 59. And below, within another cut part one remarks a rod surface 50 of a channeled rod 55 as means for mechanically sticking the rod into the composite. One sees a longitudinal spread 44.
FIG. 4 shows the section area 42′ of the T shape 27 which comprises a upper part 31, a central part 32, a foot section 33, a central excedent 35, a superior curve 36, an inferior curve 37, a mortise 38 and an inserted rod 48.
FIG. 5 shows a section area 42″ of a reverse U shape 26. A top web 70 is lightened by means of four voids 45 and extension legs 72 are thin and reinforced by reinforcing rods 48′.
FIG. 6 shows a section area 42′″ of an M shape profile 25. Outward legs 74 support a flat top 76 in conjunction with a central leg 78.
FIGS. 7A, 7B et 7C show three examples of long assemblies 60, 60′ including a stage assembly 61 made of a wood-plastic composite comprising two long bodies 62,62′ and a double step feature 63 disposed according to an internal axis of inertia 64 or an external axis of inertia 65. A lower protuberance 66,66′,66″ is found in a position to fight against tension stresses, the protuberance comprising reinforcing rods 48,48′,48″. In FIG. 7C a step lower extension 67 is included. The parts appear with partial cut for illustration purposes and are identified as cuts. Reinforcing rods are located in areas subjected to greater stresses in tension or even in compression. When a part is disposed vertically it is subjected to buckling stresses which may be compensated in the same manner by reinforcing rods.
FIGS. 8A, 8B and 8C show spreaded legs 80 to increase a support base. The flat top 70 may have a flat dome 82 or a curved dome 84, in addition to angled ears 86. Side lower extensions 88 may be provided to increase the effectiveness of the reinforcing rod 48.
FIGS. 9A and 9B show in 9A a top extension 90 to increase the breadth of the top web 70; in 9B a siding board 92 is shown with angular ribs 94 which may also be strengthened by the use of a reinforcing rod 48. A plastic coating 99 may be coextruded simultaneously with the wood-plastic composite to protect the surface against weathering. The coating is a capping to prevent color fading caused by UV rays. The coating may be used with various types of wood-plastic structures.
Instructions in a Manufacturing Process
It is initially preferred to extrude a principal part while inserting the rod through the matrix in desired places, the position of the rod being given according to the application. The driving force of the profile exiting the extrusion die feeds the rod while cooling. The internal pressure caused by material shrinking when cooling facilitates the mechanical or the chemical bond between the rod and the composite. The principal parts could be designed in multiple ways: in the shape of I, in the form of H, of a T shape beam, of an M shape beam, a rectangular form, with horizontal or vertical protrusions or according to various structural forms. In an application in bending, when a pressure is exerted on the forms on the top, there are important stresses in compression above a neutral axis and the tension resulting under the neutral axis of the form will be supported by new resistance brought by the rod to the bottom of the form. Rods could be also inserted inside the higher parts and central parts of the forms mentioned to increase the compressive strength of these forms. The rod can be striated, machined, be threaded or undergo any other surface treatment likely to support a mechanical or chemical adhesion between the rod and the composite in order to prevent this one from slipping upon the force of the pressure.

SUMMARY

The present invention consists of an assembly of materials, particularly wood-plastic composite or polymer for construction or building purposes, consisting in a matrix of these materials wherein a rod is inserted, a cable or a chord of reinforcement in a place of the tension loads, to increase the total capacity of mechanical resistance of the assembly and more particularly flexural properties. The invention thus consists of a solidified matrix using one or several rods inserted in the matrix so that the rod takes the tension stresses to increasing resistance to bending. A hardening resin may be injected in the place of a rod, or combined with it. The rods are inserted in the area undergoing the maximum of tension or at any other place in order to offer durability and an increased resistance. Various configurations of assemblies can be used, such as for example, a T, an I, a M, a H or any other form of section.
The invention is particularly useful for wood-plastic composites, a composition usually non performing in bending. Wood-plastic composites can include various mixtures of polymers, cellulosic fibers, or even a material 100% polymer. The structural matrix includes a section area and a longitudinal spread; the section area includes a lower part prone to tension stresses, the section area and the spread define a volume of a first material having a first coefficient of expansion, the compound product or polymer can be manufactured in multiple ways:

- in extrusion as a constant section and produced by the passage through an external die,
- by molding coming for example from a mold in two lengthened parts,
- by manufacturing, if two parts or more must be assembled and preserve a common longitudinal part,
- by rolling, if a part is made up of several layers, therefore lengthened;

The rod is regarded as a structural part, thin and lengthened, having a certain rigidity and a tensile strength higher than that of the wood-plastic above,

- the material of the rod must be compatible with the plastic wood composite of the matrix, particularly compatible in thermal expansion,
- the materials of the rod include glass fibre, textured steel, threaded steel, carbon fibre, fibre of Kevlar or a fibre material laid out longitudinally, or any other duly applicable fibre;
- the rod can come from a coated cable of a resin which hardens by various means including UV and which binds the cable to the matrix,
- the rod can be produced by one of the following processes: in extrusion, in “Pultrusion”, in rolling, for example if glass fibre, in brading, as for a resin coated cable; in a steel braided cable;
- the rod can be of smooth surface compatible with material of the matrix. To ensure a bond, a smooth rod can be modified, be threaded in ribbon, machined into a screw pitch or be machined to provide a surface roughness.

The reinforcing rod includes a length corresponding to said longitudinal spread, an external surface including means of contact with first material of the matrix and an internal composition defining a second material having a second coefficient of expansion identical or at least compatible with the first coefficient of expansion,

- the second material having a tensile strength at least higher than the resistance of first material reinforcing the structural part. The surface of the section of the structural matrix can be of a reversed U-shape, in the shape of an I, the form of an M, the shape of H or another form which allows the reinforcement by rod of a low part. The maximum of reinforcement is possible in the lowest part of the low part. Though with less effectiveness one can reinforce the center of the low part all the same. It is also possible to install a rod in a higher part of the low part although the rod is not subjected to as much tension stress. Higher than a neutral zone the rod will be subjected to compression. External surface of the rod includes means for rough contacts to grip the rod to the structural matrix. The means of contact can be in nets or any other surface treatment to make it rough, to give a gripping of the rod to the structural matrix. The means of contact can be striated. The second material, that of the rod is selected for having a second coefficient of expansion compatible with that of the structural matrix, to remain in place in the matrix but the tensile strength is larger than the resistance of first material, thus reinforcing the structural part. In certain applications resistance is of approximately double that of the matrix. Materials can be selected so that the tensile strength is triple or even more. A structural part comprising
- a structural matrix including a section area and a longitudinal spread, the section area including a low part prone to tension loads, the section area and spread defining a volume of a first material having a first coefficient of expansion,
- a rod including a length corresponding to the longitudinal spread and an external surface including means for contacting first material of the matrix and an internal composition defining a second material having a second coefficient of expansion compatible with the first,
- the second material having a tensile strength sensibly larger than that of the resistance of the first material for reinforcing the structural part.
  A reinforced structural part intended to solidify materials and including;
- a structural body composed of a first material, equipped with a first coefficient of expansion,
- a reinforcing rod made up of a second material equipped with a second coefficient of expansion compatible with the first coefficient, the material of the rod having a tensile strength at least greater than that of the structural body,
- means for insertion of the reinforcing rod in the structural body in order to carry out the reinforcement of the structural part. The reinforced structural part may comprise
- a principal body including a higher part, a central part and a lower part;
- the central part being able to be used to insert another part and comprising a higher curve and a lower curve;
- a reinforcing rod, inserted in the lower part being used to prevent the bending of the structure, the rod in the center being without tension, being used as reinforcement of safety and a higher rod being used for compression. Several models of lengthened structural parts 60 of composites wood-plastic include a body lengthened 62 according to an axis of inertia 64 and one protuberance at bottom 66 intended to account for tension loads, the protuberance including a reinforcing rod 48 intended to support the efforts preferentially. The reinforcing rod can be round or take a hexagonal form 49; it can be of spangled form or any other form facilitating the joining of the rod with the matrix.

It is understood that the embodiment of the present invention described above, referring to the annexed drawing is indicative but not restrictive in any way, and that modifications and adaptations can be made to the object without deviating from the bounds of the present invention.

LEGEND

20—Structural assembly
22—I shape
24—Block shape
25—M Profile
26—Reverse U shape
27—T shape
31—Upper Part
32—Central Part
33—Foot Section
35—Central Excedent
36—Superior Curve
37—Inferior Curve
38—Mortise
40—Structural Matrix
42—Section Area
44—Longitudinal Spread
45—Voids
46—Lower Part
47—Wall
48—Reinforcing Rod
49—Central Rod
50—Rod Surface
52—Rod Adhesive
53—Contact Surface
54—Palm Foot
55—Channeled Rod
57—Screw shape Rod
59—Abrasive Rod
60—Long Assembly
61—Stage Assembly
63—Double Stage Top
62—Long Body
64—Axis of Inertia internal
65—Axis of Inertia external
66—Lower Protuberance
67—Lower Extension
68—Upper Protuberance
70—Top Web
72—Extension Legs
74—Outward Legs
76—Flat Top
78—Central Lugs
80—Spreaded Legs
82—Flat Dome
84—Curved Dome
86—Angled Ears
88—Lower Extension
90—Top Extension
92—Lining Board
94—Angular Ribs
99—Plastic Coating

Claims

1. A structural assembly (20) of a wood-plastic composite comprising:

a structural matrix (40) of wood-plastic composite comprising a section area (42) and one longitudinal spread (44), said section area comprising a low part (46) prone to tension loads when said low part is in inflection, said section area and said spread defining a volume of a first material having a first coefficient of expansion,

a reinforcing rod (48) comprising a length corresponding to said longitudinal spread and an external surface (50) comprising means of contact with said first material of said matrix and an internal composition defining a second material having a second coefficient of expansion sensibly equal to said first coefficient of expansion,

said second material having a tensile strength at least larger than a resistance of said first material reinforcing said structural assembly.

2. The structural assembly (20) of composite wood-plastic of claim 1 wherein said low part (46) comprises a contact surface (53) comprising means of contact with said matrix, thus carrying out a fortification of said structural part.

3. The structural assembly (20) of claim 1 wherein said structural matrix has a surface of U-shaped section reversed (26).

4. The structural assembly (20) of claim 1 wherein said structural matrix has a section area in a form of T (27).

5. The structural assembly (20) of claim 1 wherein said structural matrix has a section area in the form of M (25).

6. The structural assembly (20) of claim 1 wherein said structural matrix has a section area in the form of H.

7. The structural assembly (20) of claim 1 wherein said reinforcing rod (48) forms part of a foot section (33) of said low part (46), in a zone of maximum tension.

8. The structural assembly (20) of claim 1 wherein said reinforcing rod (48) is positioned in a central part (32) along a neutral axis of inertia.

9. The structural assembly (20) of claim 1 wherein said reinforcing rod (48) forms part of a upper part (31) in compression.

10. The structural assembly (20) of claim 1 wherein two reinforcing rods form part of said low part.

11. The structural assembly (20) of claim 1 wherein said reinforcing rod comprises a surface (50) having means of contact allowing the use of a rod adhesive (52) to give a grip of said rod to said structural matrix.

12. The structural assembly (20) of claim 1 wherein said surface of said reinforcing rod comprises means of contact in screw pitch (57) to provide biting from said rod to said structural matrix.

13. The structural assembly (20) of claim 1 wherein said means of contact are grooved (55) to give a grip from said rod to said structural matrix.

14. The structural assembly (20) of claim 1 wherein said rod comes from a group of fibrous materials comprising glass fibre, carbon fibre and fibre of Kevlar.

15. The structural assembly (20) of claim 1 wherein said structural matrix is produced in pultrusion, extrusion, rolling, coextrusion with a resin.

16. The structural assembly (20) of claim 1 wherein said second material is at least 1.5 times more resistant in tension than said first material.

17. A structural part comprising:

a structural matrix (40) having with a section area(42) and a longitudinal spread (44) said section area comprising a lower part (46) prone to tension loads, said section area and said spread defining a volume of a first material having a first coefficient of expansion,

a reinforcing rod (48) comprising a length corresponding to said longitudinal spread and a rod surface (50) comprising means of contact with said first material of said matrix and an internal composition defining a second material having a second coefficient of expansion compatible with said first coefficient,

said second material having a tensile strength appreciably larger than resistance of said first material reinforcing said structural part.

18. A reinforced structural part (20) comprising;

a structural body (40) composed of a first material, having a first coefficient of expansion,

a reinforcing rod (48) composed of a second material having a second coefficient of expansion compatible with said first coefficient and more resistant in tension than said first material,

means of insertion of said reinforcing rod in said structural body in order to carry out the reinforcement of said structural part.

said structural body comprising a low part comprising at least one reinforcing rod (48) to prevent the camber of said structural part and to ensure a greater resistance in tension.

19. The reinforced structural part of claim 18 in which said principal body comprises a higher part, a central part and a lower part and of which form part at least a needle rod (49) and one higher reinforcing rod.

20. A lengthened structural part (60) of composite wood-plastic comprising a long body (62) comprising an axis of inertia (64) and one lower protuberance (66) subjected to tension loads, said protuberance comprising a reinforcing rod (48) intended to support tension efforts preferentially.